March 1, 201610 yr I punched out a roll pin on my 97 legacy outback and it seemed like it took more effort than it should have and when it finally came out it had been broken. I went to put a new pin in and it was being a real bugger to work with so I took a look at the roll pin that had come out. It was permanently compressed. Is it possible that the shaft from the transmission has a hole that is too small for standard subaru roll pins? Here's a few pictures of the pin: Here's the roll pin from the 97 legacy compared to a pin I pulled from a 99 forester last week.
March 1, 201610 yr Probably what happened is the hole wasn't lined up correctly when it was installed previously. Have to look through and make sure. If the axle is 180 off the spline is like 1/2 tooth off on the stub and it will crush the pin and can break it like that. If you don't have the special axle pin punch for Subaru axles, its easier if you stick the pin into a socket that is just small enough for the pin to be just a little loose. Put a 6" or 10" extension on the socket and use that to get the pin started.
March 1, 201610 yr Author It was hard to tell but i could see all the way through fairly well. I never took the axle off the car though, so I'll go ahead and pull the axle nut off and turn it 180 degrees and see if it looks better. Thanks for the information
March 2, 201610 yr Author Fairtax4me thanks, I turn it 180 degrees and it slipped as I had been expecting. I can't imagine the amount of force the mechanic who put that in used.
March 2, 201610 yr They go pretty easily when they're the right way. But when they're wrong... He wailed on it for sure.
March 2, 201610 yr I had one axle from NAPA that was misaligned both at "0" and "180" degrees. Just by a little... Thought I was nuts until I went back and swapped it and the second one aligned just fine.
March 2, 201610 yr the reason they are not reversible, the axle stubs have an odd number of splines. on one side the hole centers on a valley, on the other side it centers on a peak. Edited March 3, 201610 yr by johnceggleston
March 3, 201610 yr I'm just glad I read about that little quirk before changing my 1st subaru axle...
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