Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Manual — part 410

5MT-61

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

NOTE:

If necessary, use a new gear and hub assembly as

a set, when replacing the gear or hub. Because

these must engage at the specified point, avoid dis-

assembly as much as possible. If it must be disas-

sembled, mark the engaging point on the spline

beforehand.

ST1 499757002

INSTALLER

ST2 899714110

REMOVER

D: ASSEMBLY

1) Install the sleeve and the gear and hub assem-

bly by matching the alignment marks.
NOTE:

• Make sure that there is no large clearance at

both sides of ball detent after assembly.

• Use the new gear & hub assembly, if replacing

the gear or hub.

MT-00251

ST1

ST2

(A) Ball detent
(B) 1st-2nd synchronizer hub

(C) Reverse driven gear
(D) There is no large clearance at this part.

(A) 1st gear side
(B) 2nd gear side

(C) Flush surface
(D) Stepped surface

MT-01639

(A)

(D)

(B)

(C)

MT-00252

( B )

( A )

( C )

( D )

5MT-62

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

2) Install the 1st driven gear, inner baulk ring, syn-

chro cone, outer baulk ring, and gear & hub assem-

bly onto driven shaft.

NOTE:

• Take care to install the gear and hub assembly in

proper direction.

• Align the baulk ring and gear & hub assembly

with the key groove.

3) Install the 2nd driven gear bushing onto driven

shaft 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).
NOTE:

• 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.

ST1 499277200

INSTALLER

ST2 499587000

INSTALLER

4) Install the 2nd driven gear, inner baulk ring, syn-

chro cone and outer baulk ring, and insert them

onto driven shaft.
NOTE:

Align the groove in baulk ring with the 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).

ST1 499277200

INSTALLER

ST2 499587000

INSTALLER

(A) 1st driven gear
(B) Synchro cone

(C) Inner baulk ring
(D) Outer baulk ring

(E) Gear & hub ASSY

MT-02398

(D)

(E)

(C)

(B)

(A)

MT-00253

ST1

ST2

(A) 2nd driven gear
(B) Synchro cone

(C) Inner baulk ring
(D) Outer baulk ring

(A)

(B)

(C)

(D)

MT-02396

MT-02403

ST1

ST2

5MT-63

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

6) Install a set of double taper roller bearings onto

the driven shaft 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).
NOTE:

Use a new double taper roller bearing.

ST1 499277200

INSTALLER

ST2 499587000

INSTALLER

7) Position the woodruff key in groove of the rear of

driven shaft. Install the 5th driven gear to the driven

shaft 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 499277200

INSTALLER

ST2 499587000

INSTALLER

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.

ST1 499987300

SOCKET WRENCH (50)

ST2 899884100

HOLDER

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).

MT-02404

ST1

ST2

MT-02405

ST1

ST2

(A) Lock nut
(B) Lock washer

(C) Nut side

ST2

ST1

MT-02391

(A)

(B)

(C)

MT-00259

5MT-64

Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

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 onto the drive pinion

shaft.
NOTE:

• Use a new roller bearing.

• When installing the roller bearing, direct the

knock pin hole of outer race toward rear.

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).

ST1 499277100

BUSHING 1-2 INSTALLER

ST2 499277200

INSTALLER

13) Install the thrust bearing and needle bearing.

Install the driven shaft assembly.

(A) Lock nut
(B) Outer dimension after crimping

(A) Roller bearing
(B) Knock pin hole

(B)

(A)

MT-02707

MT-00260

(A)

(B)

(A) Washer

MT-00261

(A)

ST1

ST2

MT-00262