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Component Disassembly & Reassembly: MAINSHAFT: Reassembly

  1. Assemble sleeve and hub assemblies by inserting 3 shifting inserts, coupling sleeve, and 2 synchro springs onto hub. Position open ends of springs 120 degrees apart. Align grooves on inner surface of coupling sleeve with shifting inserts. Grooves are also marked on end face of sleeve.
  2. On 4WD dual range and full time models, assemble shifting inserts, one high-low coupling sleeve, and 2 high-low synchro rings onto high-low synchro hub. Position spring ends 120 degrees apart.
  3. On all models, install 3rd drive gear, baulk ring, and sleeve and hub assembly. Align groove in baulk ring with shifting insert. Press 4th needle bearing race onto mainshaft. Install baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer. Install thrust washer with grooves against gear. See Fig 1.
    Fig 1: Identifying 4th & 5th Gear Thrust Washers
    G93H25525Courtesy of SUBARU OF AMERICA, INC.
  4. Press ball bearing onto rear of mainshaft. Press 5th gear thrust washer and 5th needle bearing race onto mainshaft. Ensure grooves in thrust washer face 5th gear side.
  5. Install needle bearing, 5th drive gear, baulk ring, hub assembly, insert stopper plate, lock washer, and lock nut. Align groove on baulk ring with shifting insert. Engage insert stopper plate pawl with hole in synchro hub boss. Tighten lock nut to 83-91 ft. lbs. (112-124 N.m).
  6. On 4WD dual range and full time models, install needle bearing, ball, input low gear spacer (grooved side toward input gear), needle bearing, input low gear, high-low baulk ring, and sleeve and hub assembly onto front section of mainshaft. Align high-low baulk ring groove with shifting insert.
  7. Install new outer snap ring onto mainshaft. Measure clearance between snap ring and hub. Select snap ring to obtain clearance of .0024-.0039" (.060-.10 mm). Snap rings are available in thicknesses from .0933-.1071" (2.37-2.72 mm) in .002" (.05 mm) increments.


  1. Assemble each sleeve and hub by installing shifting inserts, coupling sleeve and synchro springs onto each hub. Position curved areas of springs on both sides 180 degrees apart and properly hooked in hub holes.
  2. Install 5th needle bearing race onto mainshaft. Install 3rd gear, ring and sleeve, and sleeve and hub assembly. Align insert with ring groove. Install 5th needle bearing race. Install ring, 4th gear and thrust washer. Press ball bearing into place.
  3. Select and install snap ring to obtain bearing axial play of .002" (.05 mm). Snap rings are available in thicknesses from .094-.106" (2.39-2.69 mm) in .001" (.02 mm) increments. Install Woodruff key and 5th drive gear. Tighten lock nut to 54-62 ft. lbs. (73-84 N.m).
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