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Counter Gear: Assembly

  1. Set the synchromesh shifting key spring No. 1 (A) and synchromesh shifting key No. 1 (B) to the clutch hub No. 2 (C), and install the hub sleeve No. 2 (D).
    NOTE: Make sure not to change the assembly positions for the hub sleeve No. 2 and synchromesh shifting key No. 1.
    G16526255Courtesy of SUBARU OF AMERICA, INC.
  2. Install the ball while pressing the synchromesh shifting key spring No. 1.
    CAUTION: Use vaseline and make sure the ball does not pop out.
    NOTE:
    • Apply transmission gear oil to the sliding area of the clutch hub No. 2.
    • Secure the synchromesh shifting key spring No. 1.
    G16526256Courtesy of SUBARU OF AMERICA, INC.
  3. Install the 3rd gear needle roller bearing and 3rd gear.
    NOTE: Apply transmission gear oil to the 3rd gear needle roller bearing and 3rd gear.
    G16526300Courtesy of SUBARU OF AMERICA, INC.
    (A) 3rd gear
    (B) 3rd gear needle roller bearing
    (C) Counter shaft
  4. Install the clutch hub No. 2.
    1. Install the synchronizer ring set No. 3 to the 3rd gear.
      NOTE:
      • Align the centering claw (b) with the gear groove (a).
      • Align the inner ring claw (d) with the outer ring groove (c).
      G16526301Courtesy of SUBARU OF AMERICA, INC.
      G16526302Courtesy of SUBARU OF AMERICA, INC.
    2. Install the clutch hub No. 2 using the ST1, ST2 and a press.

      Preparation tool: 

      ST1: DRIFT 2 (398477703)

      ST2: INSTALLER (18654AA000)

      CAUTION: After the installation, check that the synchronizer ring set No. 3 slides properly.
      NOTE: Press-fit the clutch hub No. 2 until it contacts the counter shaft.
    G16526303Courtesy of SUBARU OF AMERICA, INC.
  5. Install the 4th gear.
    1. Install the synchronizer ring No. 1 to the clutch hub No. 2.
      G16526304Courtesy of SUBARU OF AMERICA, INC.
    2. Install the 4th gear and 4th gear bearing inner race.
      NOTE: Apply transmission gear oil to the 4th gear and 4th gear bearing inner race.
    G16526305Courtesy of SUBARU OF AMERICA, INC.
    (A) 4th gear bearing inner race
    (B) 4th gear
    (C) Clutch hub No. 2
  6. Select a 4th inner race thrust washer.
    1. Install the 4th inner race thrust washer, 4th retaining ring washer, and snap ring that you removed in step 4 of the counter gear disassembly procedure.
      G16526306Courtesy of SUBARU OF AMERICA, INC.
      (A) Snap ring
      (B) 4th inner race thrust washer
      (C) 4th retaining ring washer
      (D) Counter shaft
    2. Remove the 4th inner race thrust washer, 4th retaining ring washer, and snap ring.
    3. Select a suitable 4th inner race thrust washer so that the thrust clearance and the clearance "C" between the 4th gear bearing inner race and the 4th inner race thrust washer are within the specified value.
      NOTE:
      • Select the thickest one that can be installed.
      • The 4th inner race thrust washer is a non-reusable part.

      Specification: 

      0 - 0.1 mm (0 - 0.004 in)

      G16526307Courtesy of SUBARU OF AMERICA, INC.
    4. Install the selected 4th inner race thrust washer, a new 4th retaining ring washer, and a new snap ring.
    G16526306Courtesy of SUBARU OF AMERICA, INC.
    (A) Snap ring
    (B) 4th inner race thrust washer
    (C) 4th retaining ring washer
    (D) Counter shaft
  7. Install the drive gear.
    1. Using the ST and a press, install the drive gear.

      Preparation tool: 

      ST: EXTENSION DRIVE SHAFT (927130000)

      G16526309Courtesy of SUBARU OF AMERICA, INC.
    2. Select a suitable snap ring so that the clearance "C" between the drive gear and snap ring is within the specified value.
      NOTE:
      • Select the thickest one that can be installed.
      • The snap ring is a non-reusable part.

      Specification: 

      0 - 0.1 mm (0 - 0.004 in)

      G16526310Courtesy of SUBARU OF AMERICA, INC.
    3. Install the selected snap ring.
    G16526311Courtesy of SUBARU OF AMERICA, INC.
    (A) Snap ring
    (B) Drive gear
  8. Install the front bearing.
    1. Using the ST and a press, install a new front bearing.

      Preparation tool: 

      ST: INSTALLER (498057300)

      G16526312Courtesy of SUBARU OF AMERICA, INC.
    2. Select a suitable snap ring so that the clearance "C" between the front bearing and snap ring is within the specified value.
      NOTE:
      • Select the thickest one that can be installed.
      • The snap ring is a non-reusable part.

      Specification: 

      0 - 0.1 mm (0 - 0.004 in)

      G16526313Courtesy of SUBARU OF AMERICA, INC.
    3. Install the selected snap ring.
G16526314Courtesy of SUBARU OF AMERICA, INC.
(A) Snap ring
(B) Front bearing
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