Counter Gear Assembly: Assembly

Installation of transmission hub sleeve No. 2
1. Apply manual transmission oil to the sliding area of the transmission clutch hub No. 2.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
2. Install the transmission hub sleeve No. 2 to the transmission clutch hub No. 2, and install the 3 balls after installing the 3 synchromesh shifting keys No. 1 and the 3 synchromesh shifting key springs No. 1 as a unit.
  NOTE:
  - Install the shifting key pole while pressing the shifting key spring. Install the balls while pressing the synchromesh shifting key spring No. 1.
  - After the installation, settle the synchromesh shifting key spring No. 1.
  Fig 1: Installing Transmission Hub Sleeve No. 2
  Courtesy of SUBARU OF AMERICA, INC.
Installation of counter shaft 3rd gear
1. Apply manual transmission oil to the counter shaft installation portion, the needle roller bearing, and the inner surface and the tapered cone portion of the counter shaft 3rd gear.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
2. Install the needle roller bearing and the counter shaft 3rd gear.
  
  Fig 2: Installing Counter Shaft 3rd Gear
  Courtesy of SUBARU OF AMERICA, INC.
Installation of transmission clutch hub No. 2
1. Install the synchronizer ring set No. 3 to the counter shaft 3rd gear.
  - Align the middle ring claw with the gear groove.
  - Align the inner ring claw with the outer ring claw groove.
2. Use the SST to install the transmission clutch hub No. 2.
  SST 18654AA000, 398477703
  
  CAUTION: Check the position of the synchronizer ring set No. 3.
  NOTE:
  - Press-fit the transmission clutch hub No. 2 until it contacts the counter shaft.
  - After the press-fitting, check that the synchronizer ring set No. 3 moves in the thrust direction.
  Fig 3: Installing Transmission Clutch Hub No. 2
  Courtesy of SUBARU OF AMERICA, INC.
Installation of counter shaft 4th gear
1. Install the synchronizer ring No. 1 to the transmission clutch hub No. 2.
2. Apply manual transmission oil to the 4th gear bearing inner race, and the inner surface and the tapered cone portion of the counter shaft 4th gear.
  NOTE: Be sure to use the recommended product or the substitute product for manual transmission oil. (Refer to MANUAL TRANSMISSION OIL )
3. Install the counter shaft 4th gear and 4th gear bearing inner race.
  NOTE: Install the 4th gear bearing inner race by turning it clockwise along the gear.
  
  Fig 4: Installing Counter Shaft 4th Gear
  Courtesy of SUBARU OF AMERICA, INC.

Installation of 4th inner race thrust washer

Select a 4th inner race thrust washer so that the thrust clearance between the 4th gear bearing inner race and the 4th inner race thrust washer is within the standard value.

Standard value: 0 to 0.1 mm {0 to 0.00394 in}

NOTE: Select a 4th inner race thrust washer with the maximum thickness that can be installed.

Type of 4th inner race thrust washer

INNER RACE THRUST WASHER SPECIFICATION

Item number	Thickness mm {in}	Identification mark
17002AA090	3.75 {0.14763}	A
17002AA100	3.80 {0.14960}	B
17002AA110	3.85 {0.15157}	C
17002AA120	3.90 {0.15354}	D
17002AA130	3.95 {0.15551}	E
17002AA140	4.00 {0.15748}	F
17002AA150	4.05 {0.15944}	G
17002AA160	4.10 {0.16141}	H

Use the SST to install a new 4th inner race thrust washer, a new 4th washer retaining ring, and a new shaft snap ring to the counter shaft.
SST 499895400

Fig 5: Installing Inner Race Thrust Washer
Courtesy of SUBARU OF AMERICA, INC.

Installation of counter drive gear
1. Use the SST to install the counter drive gear.
  SST 499277000, 398477703
  
  Fig 6: Installing Counter Drive Gear
  Courtesy of SUBARU OF AMERICA, INC.

Installation of shaft snap ring (transmission clutch hub No. 3)

Select a shaft snap ring so that the thrust clearance between the counter drive gear and the shaft snap ring is within the standard value.

Standard value: 0 to 0.1 mm {0 to 0.00394 in}

NOTE: Select a shaft snap ring with the maximum thickness that can be installed.

Shaft snap ring type

SHAFT SNAP RING SPECIFICATION

Item number	Thickness mm {in}	Identification mark
17005AA520	1.80 {0.07086}	A
17005AA530	1.85 {0.07283}	B
17005AA540	1.90 {0.07480}	C
17005AA550	1.95 {0.07677}	D
17005AA560	2.00 {0.07874}	E
17005AA570	2.05 {0.08070}	F

Use the SST to install a new shaft snap ring to the counter shaft.
SST 499895400

Fig 7: Installing Shaft Snap Ring To Counter Shaft
Courtesy of SUBARU OF AMERICA, INC.

Installation of counter gear front bearing
1. Use the SST to install a new counter gear front bearing while holding it by hand.
  SST 498057300
  
  Fig 8: Installing Counter Gear Front Bearing
  Courtesy of SUBARU OF AMERICA, INC.

Installation of shaft snap ring (counter gear front bearing)

Select a shaft snap ring so that the thrust clearance between the counter gear front bearing and the shaft snap ring is within the standard value.

Standard value: 0 to 0.1 mm {0 to 0.00394 in}

NOTE: Select a shaft snap ring with the maximum thickness that can be installed.

Shaft snap ring type

SHAFT SNAP RING SPECIFICATION

Item number	Thickness mm {in}	Identification mark
17005AA310	2.05 {0.08070}	1
17005AA290	2.10 {0.08267}	2
17005AA320	2.15 {0.08464}	3
17005AA300	2.20 {0.08661}	4
17005AA330	2.25 {0.08858}	5
17005AA340	2.30 {0.09055}	6

Use the SST to install a new shaft snap ring to the counter shaft.
SST 499895400

Fig 9: Installing Shaft Snap Ring To Counter Shaft
Courtesy of SUBARU OF AMERICA, INC.