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Home › Subaru › 2021 › WRX STI › Repair and Diagnosis › Transmission › Manual Trans › Manual Transaxle & Differential (TY856) › Driven Gear Assembly › Assembly

Driven Gear Assembly: Assembly

NOTE: When replacing the following parts, replace as a set.
  • Coupling sleeve and synchronizer hub
  • 1st outer baulk ring, 1st synchro cone and 1st inner baulk ring
  • 2nd outer baulk ring, 2nd synchro cone and 2nd inner baulk ring
  1. Apply adequate transmission gear oil to the main shaft, 1st needle bearing and 1st driven gear inner surface.
  2. Install the 1st needle bearing.
    G05003425Courtesy of SUBARU OF AMERICA, INC.
  3. Attach the 1st driven gear to the driven shaft.
    G06346052Courtesy of SUBARU OF AMERICA, INC.
  4. Install the 1st inner baulk ring.
    G06346053Courtesy of SUBARU OF AMERICA, INC.
  5. Match the protrusion of the 1st synchro cone to the hole of the 1st driven gear, then install.
    G05336185Courtesy of SUBARU OF AMERICA, INC.
  6. Install the 1st outer baulk ring.
    G05003429Courtesy of SUBARU OF AMERICA, INC.
  7. Install the 1st-2nd synchronizer hub.
    CAUTION: Apply transmission gear oil onto sliding or revolving surfaces before installation.
    NOTE:
    • Match the cut out of the 1st-2nd synchronizer hub with the protrusion on the outer baulk ring, then install.
    • Make sure that the 1st-2nd synchronizer hub is installed in the correct direction.
    G13648161Courtesy of SUBARU OF AMERICA, INC.
  8. Using the ST, install the 1st-2nd synchronizer hub and 2nd driven gear bushing.

    ST 18654AA000 INSTALLER 

    CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
    G13648162Courtesy of SUBARU OF AMERICA, INC.
  9. Make sure that the 1st driven gear can be turned smoothly by hand. If it does not turn smoothly, reassemble.
  10. Attach the 1st-2nd coupling sleeve to the 1st-2nd synchronizer hub.
    NOTE:
    • Make sure that the 1st-2nd coupling sleeve is installed in the correct direction.
    • Align the 1st-2nd synchronizer hub cut out section (three places) and the key grooves (three places) of shifting insert that are located inside the 1st-2nd coupling sleeve.
    • Set the 1st-2nd coupling sleeve and 1st driven gear so that they contact each other.
    G13648163Courtesy of SUBARU OF AMERICA, INC.
    G13648164Courtesy of SUBARU OF AMERICA, INC.
  11. Attach the 1st-2nd shifting insert to the appropriate position of the 1st-2nd coupling sleeve.
    NOTE:
    • The location angle of each shifting insert is 120°.
    • Install the 1st-2nd shifting insert to the key grooves (three places) of shifting insert that are located inside the 1st-2nd coupling sleeve.
    G13648165Courtesy of SUBARU OF AMERICA, INC.
  12. Install the 2nd outer baulk ring.
    G06346061Courtesy of SUBARU OF AMERICA, INC.
  13. Install the 2nd synchro cone.
    G05336192Courtesy of SUBARU OF AMERICA, INC.
  14. Install the 2nd inner baulk ring.
    G05003436Courtesy of SUBARU OF AMERICA, INC.
  15. Apply adequate transmission gear oil to the 2nd driven gear bushing, 2nd needle bearing and 2nd driven gear inner surface.
  16. Install the 2nd needle bearing and 2nd driven gear.
    NOTE: Match the protrusion of the 2nd synchro cone to the hole of the 2nd driven gear, then install.
    G05336194Courtesy of SUBARU OF AMERICA, INC.
  17. Attach the key.
    G05003438Courtesy of SUBARU OF AMERICA, INC.
  18. Using the ST, install the 3rd-4th driven gear.

    ST 18654AA000 INSTALLER 

    CAUTION:
    • Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
    • Apply transmission gear oil onto sliding or revolving surfaces before installation.
    NOTE:
    • Make sure that the 3rd-4th driven gear is installed in the correct direction.
    • Match the groove on the 3rd-4th driven gear to the key.
    G13648171Courtesy of SUBARU OF AMERICA, INC.
  19. Make sure that the 2nd driven gear can be turned smoothly by hand. If it does not turn smoothly, reassemble.
  20. Attach the key.
    G05003440Courtesy of SUBARU OF AMERICA, INC.
  21. Using the ST, install the 5th-6th driven gear.

    ST 18654AA000 INSTALLER 

    CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
    NOTE:
    • Make sure that the 5th-6th driven gear is installed in the correct direction.
    • Match the groove on the 5th-6th driven gear to the key.
    G13648173Courtesy of SUBARU OF AMERICA, INC.
  22. Using the ST, install the ball bearing.

    ST 18654AA000 INSTALLER 

    CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
    NOTE: Face the sealing section of the ball bearing to the lock nut side, and install the ball bearing.
    G13648174Courtesy of SUBARU OF AMERICA, INC.
  23. Make sure that the ball bearing turns smoothly by hand. If it does not turn smoothly, reassemble.
  24. Install a new lock nut.
  25. Attach ST3 to the lock nut, attach ST to the driven gear assembly, and tighten the lock nut.

    ST1 18666AA000 HOLDER 

    ST2 18664AA000 BASE 

    ST3 18620AA000 ADAPTER WRENCH 

    ST4 18852AA000 TORQUE WRENCH 

    Tightening torque: 

    530 N.m (54.0 kgf-m, 390.9 ft-lb)

    G05003443Courtesy of SUBARU OF AMERICA, INC.
    NOTE: When using a torque wrench other than ST4, use the calculation below to calculate and tighten the lock nut.

    T = L1/(0.1 + L1) x 570

    T N.m (kgf-m, ft-lb) Torque wrench setting
    L1 m (in) Torque wrench length
    0.1 m (3.94 in) Length of ST
    570 N.m (58.1 kgf-m, 420 ft-lb) Tightening torque (lock nut)
    G13648176Courtesy of SUBARU OF AMERICA, INC.
  26. Using the ST, crimp the lock nut in 4 locations, with dimensions within A 44±0.5 mm (1.73±0.02 in).

    ST 18669AA000 PUNCH DRIVEN SHAFT 

    NOTE: Do not damage the crimp area of the lock nut.
    G05003445Courtesy of SUBARU OF AMERICA, INC.
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