Subaru Crosstrek Service Manual: 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.

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.

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).

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.

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).

• Install the snap ring side of the double ball bearing facing the 5th drive gear side.

• Use a new double ball bearing.

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).

Make sure the thrust washer is facing the correct direction.

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.

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)

9. Crimp lock nuts in two locations after tightening.

CAUTION:

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

Removal

Disassembly

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