Main Shaft Assembly for Single-Range: Assembly

When the sleeve & hub assemblies have been disassembled, reassemble by aligning the alignment marks.
NOTE: Position the open ends of the spring 120° apart.

Fig 1: Identifying 3rd-4th Hub Assy And 3rd Gear Side
Courtesy of SUBARU OF AMERICA, INC.
Install the needle bearing, 3rd drive gear, outer baulk ring, 3rd synchro cone, inner baulk ring and 3rd-4th synchronizer hub on the transmission main shaft.
NOTE: Align the groove in baulk ring with the shifting insert.

Fig 2: Aligning Groove In Baulk Ring With Shifting Insert
Courtesy of SUBARU OF AMERICA, INC.
Install the 4th needle bearing race onto transmission main shaft 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

Fig 3: Installing 4th Needle Bearing Race Onto Transmission Main Shaft Using ST1, ST2, ST3 And Press
Courtesy of SUBARU OF AMERICA, INC.
Install the 3rd-4th coupling sleeve, 4th baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to the transmission main shaft.
NOTE:
- Align the 4th baulk ring and 3rd-4th synchronizer hub with the key groove.
- Install the 3rd-4th coupling sleeve with the groove side facing the 3rd drive gear.
- Install the 4th gear thrust washer with the groove side facing the 4th drive gear.
  
  Fig 4: Identifying Thrust Washer Groove
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 5: Identifying 3rd-4th Coupling Sleeve, 4th Baulk Ring, 4th Drive Gear And Needle Bearing
  Courtesy of SUBARU OF AMERICA, INC.
Install the double taper roller bearing into the rear section of transmission main shaft 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: 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

Fig 6: Installing Double Taper Roller Bearing With Snap Ring Side Facing 5th Drive Gear Side
Courtesy of SUBARU OF AMERICA, INC.
Install the 5th needle bearing race into the rear section of transmission main shaft 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).

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 7: Installing 5th Needle Bearing Race Into Rear Section Of Transmission Main Shaft Using ST1, ST2 And Press
Courtesy of SUBARU OF AMERICA, INC.
Install the needle bearing, 5th drive gear, 5th baulk ring, and 5th-6th synchronizer hub on the transmission main shaft.
NOTE:
- Align the protruded section of 5th baulk ring with concave section of 5th-6th synchronizer hub.
- Install the 5th-6th synchronizer hub with the groove side facing the 5th drive gear.
  
  Fig 8: Identifying 5th-6th Synchronizer Hub With Groove Side Facing 5th Drive Gear
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 9: Identifying 5th-6th Synchronizer Hub, 5th Drive Gear And 5th Baulk Ring
  Courtesy of SUBARU OF AMERICA, INC.
Install the 6th needle bearing race onto transmission main shaft 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).

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 10: Installing 6th Needle Bearing Race Onto Transmission Main Shaft Using ST1, ST2 And Press
Courtesy of SUBARU OF AMERICA, INC.
Install the 5th-6th coupling sleeve, 6th baulk ring, 6th drive gear and needle bearing on the transmission main shaft.
NOTE: Install the 5th-6th coupling sleeve with the short flange side facing the 5th drive gear.

Fig 11: Installing 5th-6th Coupling Sleeve, 6th Baulk Ring, 6th Drive Gear And Needle Bearing On Transmission Main Shaft
Courtesy of SUBARU OF AMERICA, INC.

Fig 12: Installing 5th-6th Coupling Sleeve With Short Flange Side Facing 5th Drive Gear
Courtesy of SUBARU OF AMERICA, INC.
Install the ball bearing onto transmission main shaft 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

Fig 13: Installing Ball Bearing Onto Transmission Main Shaft Using ST2 And Press
Courtesy of SUBARU OF AMERICA, INC.
Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE: Lock nuts and lock washers must be replaced with new parts.

Tightening torque:

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

ST1 499987003 SOCKET WRENCH (35)

ST2 498937000 TRANSMISSION HOLDER

Fig 14: Tightening Lock Nuts To Specified Torque Using ST1 And ST2
Courtesy of SUBARU OF AMERICA, INC.
Crimp lock nuts in two locations after tightening.