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Home >> Subaru >> 2018 >> Forester 2.5i, 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.
G12516299Courtesy 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.
    G12516300Courtesy 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).

    ST1 899714110 REMOVER

    ST2 499877000 RACE 4-5 INSTALLER

    ST3 398177700 INSTALLER

    G12516301Courtesy 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.
    G12516302Courtesy of SUBARU OF AMERICA, INC.
  4. Install the 3rd-4th shifting insert.
    NOTE: Press in the ball part to install.
    G12516303Courtesy 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.
    G12516304Courtesy of SUBARU OF AMERICA, INC.
    G12516305Courtesy of SUBARU OF AMERICA, INC.
  6. Install the double taper roller bearing 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).
    NOTE:
    • Use a new double taper roller bearing.
    • Install the double taper roller bearing with snap ring side facing the 5th drive gear side.

    ST1 899714110 REMOVER

    ST2 499877000 RACE 4-5 INSTALLER

    G12516306Courtesy 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 press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST1 899714110 REMOVER

    ST2 499877000 RACE 4-5 INSTALLER

    G12516307Courtesy 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.
    G12516308Courtesy of SUBARU OF AMERICA, INC.
  10. Install the 6th needle bearing race using ST1, ST2 and press.
    CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

    ST1 899714110 REMOVER

    ST2 499877000 RACE 4-5 INSTALLER

    G12516309Courtesy 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.
    G12516310Courtesy of SUBARU OF AMERICA, INC.
  12. Install the 5th-6th shifting insert.
    NOTE: Press in the ball part to install.
    G12516311Courtesy of SUBARU OF AMERICA, INC.
  13. Install the 6th baulk ring, 6th drive gear and 6th needle bearing.
    G12516312Courtesy of SUBARU OF AMERICA, INC.
  14. Install the ball bearing using 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).
    NOTE: Install the ball bearing with the side which does not have lock nut mounting dent facing 6th drive gear.

    ST1 899714110 REMOVER

    ST2 899754112 PRESS

    G12516313Courtesy of SUBARU OF AMERICA, INC.
  15. Install the lock washer.
    NOTE:
    • Use a new lock washer.
    • Install the lock washer in the correct direction.
    G12516314Courtesy of SUBARU OF AMERICA, INC.
  16. Install the lock nut using ST1 and ST2.
    NOTE: Use a new lock nut.

    Tightening torque: 

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

    ST1 498937000 TRANSMISSION HOLDER

    ST2 499987003 SOCKET WRENCH (35)

    G12516315Courtesy of SUBARU OF AMERICA, INC.
  17. Crimp the lock nut at two locations so that the dimension (B) becomes 23.3 mm (0.92 in) or less.
    CAUTION: When crimping the lock nut, be careful not to crack it.
    G12516316Courtesy of SUBARU OF AMERICA, INC.
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