Subaru Legacy BN/BS (2015-2019) Service Manual: Disassembly

Subaru Legacy BN/BS (2015-2019) Service Manual / Manual transmission and differential(6mt) / Drive pinion shaft assembly / Disassembly

NOTE:

• Attach a cloth to the end of driven shaft (on the frictional side of the thrust needle bearing) to prevent damage during disassembly or reassembly.

• When replacing the coupling sleeve and synchronizer hub, replace them as a set. Because these must engage at the specified point, avoid disassembly as much as possible. If it is necessary to disassemble, mark the engaging points on the splines beforehand.

1. Flatten the tab of the lock nut.

2. Remove the lock nut using ST1, ST2 and ST3.

ST1 18680AA020

HOLDER

ST2 18667AA020

HOLDER

ST3 18662AA010

SOCKET WRENCH (27)

3. Remove the lock washer, washer, differential bevel gear sleeve, adjusting washer No. 1, thrust bearing and adjusting washer No. 2.

(A)	Lock washer
(B)	Washer
(C)	Differential bevel gear sleeve
(D)	Adjusting washer No. 1 (25 - 36 - t)
(E)	Thrust bearing (25 - 36 - 2)
(F)	Adjusting washer No. 2 (25 - 36 - t)

4. Draw out the drive pinion shaft from driven shaft.

5. Remove the needle bearing and drive pinion collar.

(A)	Drive pinion collar
(B)	Needle bearing (25 - 30 - 20)

6. Remove the needle bearing and thrust bearing.

(A)	Needle bearing (30 - 37 - 23)
(B)	Thrust bearing (33 - 50 - 3)

7. Remove the roller bearing and washer using ST and a press.

ST 498077000

REMOVER

8. Flatten the tab of the lock nut.

9. Remove the lock nut using ST1 and ST2.

ST1 499987300

SOCKET WRENCH (50)

ST2 18680AA020

HOLDER

10. Remove the ball bearing, 6th driven gear and drive pinion spacer using the ST1, ST2 and a press.

ST1 899754112

PRESS

ST2 899714110

REMOVER

11. Remove the 5th driven gear, double ball bearing and 3rd-4th driven gear using ST1, ST2 and a press.

ST1 899754112

PRESS

ST2 899714110

REMOVER

12. Remove the key.

13. Remove the 2nd driven gear, 2nd inner baulk ring, 2nd synchro cone, 2nd outer baulk ring, 1st-2nd shifting insert and 1st-2nd coupling sleeve.

CAUTION:

When removing 1st-2nd coupling sleeve, be careful not to lose the 1st-2nd shifting insert.

14. Remove the 1st driven gear, 1st inner baulk ring, 1st synchro cone, 1st outer baulk ring, 2nd driven gear bushing and 1st-2nd synchronizer hub using ST and a press.

ST 18762AA001

COMPRESSOR SPECIAL TOOL

Inspection

Disassembled parts should be washed with cleaning solvent first, then inspected carefully.1. BearingReplace the bearings in the following cases.• When the bearing balls, outer races and inner ra ...

Assembly

NOTE:• Match the alignment marks, and install the coupling sleeve and then install the shifting insert.• Make sure that there is no large clearance at both sides of the shifting insert aft ...

Other materials:

Caution
• Prior to starting work, pay special attention to the following:1. Always wear work clothes, a work cap, and protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary.2. Protect the vehicle using a seat cover, fender cover, etc.3. Prepare the service tools, clean cl ...