LEMON Manuals: Even more car manuals for everyone
Home >> Subaru >> 2018 >> Crosstrek Base, Standard Trans >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transaxle & Differential >> Main Shaft Assembly >> Assembly

Main Shaft Assembly: Assembly

NOTE:
  • Match the alignment marks, and install the coupling sleeve and then install the shifting insert.
  • Make sure that there is no large clearance at both sides of the shifting insert after assembly.
G12394921Courtesy of SUBARU OF AMERICA, INC.
  1. Install the 3rd needle bearing, 3rd drive gear, 3rd outer baulk ring, 3rd synchro cone, 3rd inner baulk ring and 3rd-4th synchronizer hub.
    NOTE:
    • Install the 3rd-4th synchronizer hub in the correct direction.
    • Align the protrusion of the 3rd outer baulk ring into the groove of the 3rd-4th synchronizer hub.
    G12394922Courtesy of SUBARU OF AMERICA, INC.
  2. Install the 4th needle bearing race using ST1, ST2, ST3 and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    Special tool: 

    ST1: 899714110 REMOVER

    ST2: 499877000 RACE 4-5 INSTALLER

    ST3: 398177700 INSTALLER

    G12394923Courtesy of SUBARU OF AMERICA, INC.
  3. Install the 3rd-4th coupling sleeve.
    NOTE:
    • Install the 3rd-4th coupling sleeve in the correct direction.
    • Align the alignment marks of 3rd-4th coupling sleeve and the 3rd-4th synchronizer hub.
    G12394924Courtesy of SUBARU OF AMERICA, INC.
  4. Install the 3rd-4th shifting insert.
    NOTE: Press in the ball part to install.
    G08582047Courtesy of SUBARU OF AMERICA, INC.
  5. Install the 4th baulk ring, 4th needle bearing, 4th drive gear and 4th gear thrust washer.
    NOTE:
    • Align the protrusion of the 4th baulk ring into the groove of the 3rd-4th synchronizer hub.
    • Install the 4th gear thrust washer with the groove side facing the 4th drive gear.
    G12394926Courtesy of SUBARU OF AMERICA, INC.
    G12394927Courtesy of SUBARU OF AMERICA, INC.
  6. Install a new double taper roller bearing using the ST1, ST2 and a press.
    CAUTION:
    • Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    • Install the double taper roller bearing with its snap ring side facing the 5th drive gear side.

    Special tool: 

    ST1: 899714110 REMOVER

    ST2: 499877000 RACE 4-5 INSTALLER

    G08582050Courtesy of SUBARU OF AMERICA, INC.
  7. Make sure that the double taper roller bearing turns smoothly.
  8. Install the 5th needle bearing race using ST1, ST2 and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    Special tool: 

    ST1: 899714110 REMOVER

    ST2: 499877000 RACE 4-5 INSTALLER

    G12394929Courtesy of SUBARU OF AMERICA, INC.
  9. Install the 5th needle bearing, 5th drive gear, 5th baulk ring, and 5th-6th synchronizer hub.
    NOTE:
    • Align the protrusion part of the 5th baulk ring with the groove of the 5th-6th synchronizer hub.
    • Install the 5th-6th synchronizer hub in the correct direction.
    G12394930Courtesy of SUBARU OF AMERICA, INC.
  10. Install the 6th needle bearing race using ST1, ST2 and a press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    Special tool: 

    ST1: 899714110 REMOVER

    ST2: 499877000 RACE 4-5 INSTALLER

    G12394931Courtesy of SUBARU OF AMERICA, INC.
  11. Install the 5th-6th coupling sleeve.
    NOTE:
    • Install the 5th-6th coupling sleeve in the correct direction.
    • Align the alignment marks of 5th-6th coupling sleeve and the 5th-6th synchronizer hub.
    G12394932Courtesy of SUBARU OF AMERICA, INC.
  12. Install the 5th-6th shifting insert.
    NOTE: Press in the ball part to install.
    G08582055Courtesy of SUBARU OF AMERICA, INC.
  13. Install the 6th baulk ring, 6th drive gear and 6th needle bearing.
    G12394934Courtesy of SUBARU OF AMERICA, INC.
  14. Using the ST2 and a press, install the ball bearing.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    NOTE: Install the ball bearing with the side which does not have lock nut mounting dent facing 6th drive gear.

    Special tool: 

    ST1: 899714110 REMOVER

    ST2: 899754112 PRESS

    G08582057Courtesy of SUBARU OF AMERICA, INC.
  15. Install a new lock washer.
    CAUTION: Make sure the lock washer is facing the correct direction.
    G12394936Courtesy of SUBARU OF AMERICA, INC.
  16. Install a new lock nut using the ST1 and ST2.

    Tightening torque: 

    160 N.m (16.3kgf-m, 118.0ft-lb)

    Special tool: 

    ST1: 498937000 TRANSMISSION HOLDER

    ST2: 499987003 SOCKET WRENCH (35)

    G08582038Courtesy of SUBARU OF AMERICA, INC.
  17. Crimp the lock nut at two locations so that the dimension (B) becomes 23.3 mm (0.92in) or less.
    CAUTION: When crimping the lock nut, be careful not to crack it.
    G12394938Courtesy of SUBARU OF AMERICA, INC.
scientia non olet · About LEMON Manuals