Subaru Crosstrek Service Manual: Assembly

1. Install the sleeve and the gear and hub assembly by matching the alignment marks.

NOTE:

• Make sure that there is no large clearance at both sides of the 1st-2nd shifting insert after assembly.

2. Install the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, and gear & hub assembly.

NOTE:

• Install the gear & hub assembly in the proper position while paying attention to the installing direction.

• Align the baulk ring and gear & hub assembly with the key groove.

3. Install the 2nd driven gear bushing 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).

• Attach a cloth to the end of the driven shaft to prevent damage.

• When press fitting, align the oil holes of the shaft and bushing.

4. Attach and insert the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.

NOTE:

Align the groove of the baulk ring with the 1st-2nd shifting insert.

5. After installing key onto the driven shaft, install the 3rd-4th driven gear 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).

6. Install the set of double taper roller bearing 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).

Use a new double taper roller bearing.

7. Position the woodruff key in groove of the rear of driven shaft. Install the 5th driven gear 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).

Face the groove for identification of the 5th driven gear toward the nut.

8. Install the lock washer. 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:

260 N·m (26.5 kgf-m, 191.8 ft-lb)

9. Using a spring scale, check that starting torque of the double taper roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.34 lbf).

10. Crimp the lock nut at two locations so that the dimension (B) becomes 41.1 mm (1.62 in) or less.

CAUTION:

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

11. Install the roller bearing.

NOTE:

• Use a new roller bearing.

• Install with the knock pin hole of the roller bearing outer race facing the rear side.

12. Install the washer 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).

13. Install the thrust bearing and needle bearing and install the driven shaft assembly.

14. Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in this order.

15. Adjust the thrust bearing preload. Drive Pinion Shaft Assembly > ADJUSTMENT">

Removal

Disassembly

Other materials:

Inspection
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Removal
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Dtc c0041 ecm
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