Subaru Crosstrek Service Manual: Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Main Shaft Assembly
ASSEMBLY
1. When the sleeve & hub assemblies have been disassembled, reassemble by aligning the alignment marks.
NOTE:
Position the open ends of the spring 120° apart.
(A) | 3rd-4th coupling sleeve & synchronizer hub ASSY |
(B) | 3rd gear side |
2. 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.
(A) | 3rd needle bearing |
(B) | 3rd drive gear |
(C) | Inner baulk ring |
(D) | 3rd synchro cone |
(E) | Outer baulk ring |
(F) | Sleeve & hub ASSY |
3. 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 |
(A) | 4th needle bearing race |
4. 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.
(A) | Groove |
(B) | Face this surface to the 4th gear side. |
5. 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 |
6. 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 |
(A) | Face this surface to the 5th gear side. |
7. 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.
(A) | Baulk lever |
(B) | 5th hub |
• Align the protruded section of the 5th baulk ring between the baulk levers.
(A) | 5th baulk ring |
(B) | Baulk lever |
(C) | 5th hub |
8. 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 |
(A) | 5th needle bearing |
(B) | 5th drive gear |
(C) | 5th baulk ring |
(D) | 5th hub & sleeve No. 2 |
(E) | Lock washer |
(F) | Lock nut |
(G) | Baulk lever |
(H) | Nut side |
9. Crimp lock nuts in two locations after tightening.
CAUTION:
When crimping the lock nut, be careful not to crack it.
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