Main Shaft Assembly: 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: Alignment Marks On 3Rd Gear Side And 3Rd-4Th Coupling Sleeve & Synchronizer Hub Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the 3rd drive gear, outer baulk ring, 3rd synchro cone, inner baulk ring, 3rd needle bearing, and sleeve & hub assembly.
NOTE: Align the groove of the baulk ring with the 3rd-4th shifting insert.

Fig 2: 3Rd Drive Gear, Outer Baulk Ring, 3Rd Synchro Cone, Inner Baulk Ring, 3Rd Needle Bearing And Sleeve & Hub Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the 4th needle bearing race 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 3: Installing 4Th Needle Bearing Race Using Remover (899714110) And Race 4-5 Installer (499877000)
Courtesy of SUBARU OF AMERICA, INC.
Install the 4th baulk ring, 4th needle bearing, 4th drive gear, and 4th gear thrust washer to the main shaft.
NOTE:
- Align the 4th baulk ring and hub & sleeve assembly with the key groove.
- Make sure the thrust washer is facing the correct direction.
Fig 4: Aligning 4Th Baulk Ring And Hub & Sleeve Assembly With Key Groove
Courtesy of SUBARU OF AMERICA, INC.
Press-fit the double ball bearing with 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 snap ring side of the double ball bearing facing the 5th drive gear side.
- Use a new double ball bearing.
ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 5: Pressing-Fit Double Ball Bearing With Remover (899714110) And Race 4-5 Installer (499877000)
Courtesy of SUBARU OF AMERICA, INC.
Using the ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of the main shaft.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Make sure the thrust washer is facing the correct direction.

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 6: Checking Thrust Washer Facing In Correct Direction
Courtesy of SUBARU OF AMERICA, INC.
Install the rest of the parts to the rear section of the main shaft.
CAUTION:
- Install the baulk lever so that the concave side faces toward the 5th hub.
  
  Fig 7: Installing Rest Of Parts To Rear Section Of Main Shaft
  Courtesy of SUBARU OF AMERICA, INC.
- Align the protruded section of the 5th baulk ring between the baulk levers.
Fig 8: Aligning Protruded Section Of 5Th Baulk Ring Between Baulk Levers
Courtesy of SUBARU OF AMERICA, INC.
Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE:
- Use new lock nuts and lock washers.
- Make sure the lock washer is installed in the proper direction.
Tightening torque:

120 N.m (12.2 kgf-m, 88.5 ft-lb)

ST1 499987003 SOCKET WRENCH (35)

ST2 498937000 TRANSMISSION HOLDER

Fig 9: 5Th Needle Bearing, 5Th Drive Gear, 5Th Baulk Ring, 5Th Hub & Sleeve No. 2, Lock Washer, Lock Nut, Baulk Lever And Nut
Courtesy of SUBARU OF AMERICA, INC.
Crimp lock nuts in two locations after tightening.

CAUTION: When crimping the lock nut, be careful not to crack it.