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Drive Pinion Shaft Assembly: Installation

  1. Remove the front differential assembly.
  2. Hypoid gear set match mark/No.: The number (A) on top of the drive pinion, and the number on the hypoid driven gear are set numbers for the two gears. Use a pair having the same numbers.

    The figure (B) below shows a number for shim adjustment. If no number is shown, the value is zero.

    Fig 1: Identifying Set Number And Number For Shim Adjustment
    G08582066Courtesy of SUBARU OF AMERICA, INC.
  3. Place the drive pinion shaft assembly on transmission main case RH without shim and tighten the bearing mounting bolts.
  4. Perform the adjustment of ST.
    NOTE:
    • Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level.
    • Tighten the two bolts.

    ST 499917500 DRIVE PINION GAUGE ASSY

    Fig 2: Tightening Bearing Mounting Bolts Using Special Tool (When Plate End And Scale End Are At Same Level)
    G08582067Courtesy of SUBARU OF AMERICA, INC.
  5. Position the ST by inserting the knock pin of ST into the knock hole of transmission case.

    ST 499917500 DRIVE PINION GAUGE ASSY

  6. Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion.

    ST 499917500 DRIVE PINION GAUGE ASSY

    Fig 3: Positioning Special Tool By Inserting Knock Pin Of Special Tool Into Knock Hole Of Transmission Case
    G08582068Courtesy of SUBARU OF AMERICA, INC.
  7. The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the ST. (Add if the number on drive pinion is prefixed by +, and subtract if the number is prefixed by -.)
  8. Select one to three shims in the following table for the value determined as described above, and take the shim(s) whose thickness is closest to the said value.
    NOTE: Install the shim with it's cut in facing the shifter fork & rod side.
    Drive pinion shim
    Part No. Thickness mm (in)
    32295AA031 0.150 (0.0059)
    32295AA041 0.175 (0.0069)
    32295AA051 0.200 (0.0079)
    32295AA061 0.225 (0.0089)
    32295AA071 0.250 (0.0098)
    32295AA081 0.275 (0.0108)
    32295AA091 0.300 (0.0118)
    32295AA101 0.500 (0.0197)
  9. Install the front differential assembly. Refer to INSTALLATION .
  10. Fit the transmission case knock pin to the knock pin hole of the roller bearing and install the drive pinion shaft assembly.
  11. Install the main shaft assembly for single-range. Refer to INSTALLATION .
  12. Check each shifter fork. Refer to INSPECTION .
  13. Install the transmission case. Refer to INSTALLATION .
  14. Install the transfer case together with the extension case assembly. Refer to INSTALLATION .
  15. Install the manual transmission assembly to the vehicle. Refer to INSTALLATION .
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