Main Shaft Assembly For Dual-Range - Subaru 2004 Impreza Service Manual

MANUAL TRANSMISSION AND DIFFERENTIAL
17.Main Shaft Assembly for
Dual-Range
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to 5MT-38, REMOVAL, Manual
Transmission Assembly.>
2) Remove the transfer case with extension case
assembly. <Ref. to 5MT-53, REMOVAL, Transfer
Case and Extension Case Assembly.>
3) Remove the transmission case. <Ref. to 5MT-
66, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly. <Ref.
to 5MT-91, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly and input shaft
assembly.
B: INSTALLATION
1) Install the needle bearing onto the front of trans-
mission main shaft assembly.
2) Connect the main shaft assembly and input shaft
assembly.
3) Install the needle bearing outer race knock pin
hole into transmission case knock pin.
4) Install the drive pinion assembly. <Ref. to 5MT-
91, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
5) Install the transmission case. <Ref. to 5MT-68,
INSTALLATION, Transmission Case.>
6) Install the transfer case with extension case as-
sembly. <Ref. to 5MT-53, INSTALLATION, Trans-
fer Case and Extension Case Assembly.>
7) Install the manual transmission assembly to ve-
hicle. <Ref. to 5MT-41, INSTALLATION, Manual
Transmission Assembly.>
C: DISASSEMBLY
1) Put vinyl tape around the main shaft splines to
protect oil seal from damage. Then pull out the oil
seal and needle bearing by hand.
2) Remove the lock nut from transmission main
shaft assembly.
NOTE:
Remove the caulking before taking off lock nut.

Main Shaft Assembly for Dual-Range

5MT-82
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
ST2
3) Remove the 5th-Rev sleeve and hub assembly,
baulk ring, 5th drive gear and needle bearing.
(A) 5th-Rev sleeve and hub ASSY
(B) Baulk ring
(C) 5th drive gear
4) Remove the snap ring and synchro cone stopper
from 5th-Rev sleeve and hub assembly.
(A) Synchro cone stopper
(B) Snap ring
5) Using the ST1, ST2 and a press, remove the ball
bearing, synchro cone and baulk ring (Rev).
NOTE:
• Replace the sleeve and hub with new ones. Do
not attempt to disassemble because they must en-
gage at a specified point. If they should be disas-
sembled, mark engagement point on splines
beforehand.
ST1
MT-00186
( C )
( B )
( A )
MT-00187
(B)
(A)
MT-00188