Drive Pinion Shaft Assembly: Disassembly

NOTE:

Attach a cloth to the end of driven shaft (on the frictional side of the thrust needle bearing) to prevent damage during disassembly or reassembly.
When replacing the coupling sleeve and synchronizer hub, replace them as a set.
Coupling sleeve and synchronizer hub position is pre-matched. Mark the engaging points on the splines before disassembly.

Flatten the tab of the lock nut.
Remove the lock nut using ST1, ST2 and ST3.
ST1 18680AA020 HOLDER

ST2 18667AA020 HOLDER

ST3 18662AA010 SOCKET WRENCH (27)

Fig 1: Removing Lock Nut Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Remove the lock washer, washer, differential bevel gear sleeve, adjusting washer No. 1, thrust bearing and adjusting washer No. 2.

Fig 2: Identifying Lock Washer, Washer, Differential Bevel Gear Sleeve, Adjusting Washer No. 1, Thrust Bearing And Adjusting Washer No. 2
Courtesy of SUBARU OF AMERICA, INC.
Draw out the drive pinion shaft from driven shaft.
Remove the needle bearing and drive pinion collar from driven shaft.

Fig 3: Identifying Drive Pinion Collar And Needle Bearing
Courtesy of SUBARU OF AMERICA, INC.
Remove the needle bearing and thrust bearing from drive pinion shaft.

Fig 4: Identifying Needle Bearing And Thrust Bearing
Courtesy of SUBARU OF AMERICA, INC.
Remove the roller bearing and washer using ST and a press.
NOTE: Do not reuse the roller bearing.

ST 498077000 REMOVER

Fig 5: Removing Roller Bearing And Washer Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Flatten the tab of the lock nut.
Remove the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)

ST2 18680AA020 HOLDER

Fig 6: Removing/Installing Lock Nut Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Remove the ball bearing, 6th driven gear and drive pinion spacer using the ST1, ST2 and a press.
ST1 899754112 PRESS

ST2 899714110 REMOVER

Fig 7: Removing Ball Bearing, 6th Driven Gear And Drive Pinion Spacer Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Remove the ball bearing and 3rd-4th driven gear using ST1, ST2 and a press.
NOTE: Do not reuse the ball bearing.

ST1 899754112 PRESS

ST2 899714110 REMOVER

Fig 8: Removing Ball Bearing And 3rd-4th Driven Gear Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Remove the key.
Remove the 2nd driven gear, inner baulk ring, synchro cone, outer baulk ring, shifting insert and 1st-2nd coupling sleeve.
CAUTION: When removing 1st-2nd coupling sleeve, be careful not to lose the shifting insert.
Remove the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, 2nd gear bushing and 1st-2nd synchronizer hub using ST and a press.
ST 18762AA000 COMPRESSOR SPECIAL TOOL

Fig 9: Removing 1st Driven Gear, Synchro Cone, Inner And Outer Baulk Ring, 2nd Gear Bushing And 1st-2nd Synchronizer Hub Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.