Front Differential Assembly
Front Differential AssemblyREMOVAL
1. Remove the transmission assembly from vehicle.
2. Pull out the torque converter assembly.
3. Remove the transmission harness connector from stay.
4. Remove the oil charge pipe.
5. Remove the ATF filter inlet and outlet pipes.
6. Separate the converter case and transmission case.
7. Remove the differential side retainers using ST.
NOTE: Hold the differential case assembly by hand to avoid damaging the retainer mounting hole of converter case.
ST 18630AA010 WRENCH COMPL RETAINER
8. Remove the differential assembly without damaging the installation part of retainer.
INSTALLATION
1. When installing the differential assembly to case, be careful not to damage the inside of case (particularly, the differential side retainer mating surface).
2. Install the O-ring to left and right side retainer.
3. Install the side retainers using ST.
ST 18630AA010 WRENCH COMPL RETAINER
4. Adjust the front differential backlash.
5. Install the lock plate.
Tightening torque: 25 Nm (2.5 kgf-cm, 18 ft. lbs.)
6. Install the converter case to transmission case.
7. Install the transmission harness connector to the stay.
8. Install the ATF filter pipe.
9. Install the oil charge pipe with a O-ring.
10. Install the torque converter assembly.
11. Install the transmission assembly into vehicle.
DISASSEMBLY
DIFFERENTIAL CASE ASSEMBLY
1. Remove the taper roller bearing using ST and press.
ST 498077000 REMOVER
2. Secure the case in a vise and remove the hypoid driven gear tightening bolts, then separate the hypoid driven gear case (RH) and case (LH).
3. Pull out the straight pin and shaft, and then remove the differential bevel gear, washer and differential bevel pinion.
SIDE RETAINER
NOTE: After adjusting the drive pinion backlash and tooth contact, remove and install the oil seal and O-ring.
1. Remove the O-ring.
2. Remove the oil seal.
3. Remove the split pin, and then remove the claw.
ST 398527700 PULLER ASSY
4. Attach two claws to the outer race, and set the ST to side retainer.
ST 398527700 PULLER ASSY
5. Restore the removed claws to original position, and install the pin and split pin.
6. Hold the shaft of ST to avoid removing from side retainer, and then remove the bearing outer race.
ST 398527700 PULLER ASSY
NOTE: Replace the bearing inner and outer races as a single unit.
ASSEMBLY
DIFFERENTIAL CASE ASSEMBLY
1. Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH). Insert the pinion shaft.
2. Install the straight pin in reverse direction.
3. Install the washer and differential bevel gear to differential case (LH). Put the differential case (RH) on the case, and then combine the both cases.
4. Install the hypoid driven gear and secure by tightening the bolt.
Tightening torque: 62 Nm (6.3 kgf-cm, 45.6 ft. lbs.)
5. Measurement of backlash (Selection of washer)
1. Install the SUBARU genuine axle shaft to differential case.
Parts No. 38415AA070AXLE SHAFT
2. Measure the gear backlash using ST1 and ST2, and then insert the ST2 from the access window of case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
^ Measure the backlash by applying a pinion tooth between two bevel gear teeth.
^ Fix the bevel pinion gear in place with a screwdriver or similar tool when measuring.
Standard value: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
3. If the backlash is not within specifications, select a washer from the table below.
6. Using the ST, install the taper roller bearing.
ST 398487700 DRIFT
SIDE RETAINER
NOTE: Install the oil seal and O-ring of side retainer after the adjustment of backlash and tooth contact.
1. Install the bearing outer race to side retainer.
2. Fit a new oil seal using ST.
ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
NOTE: Apply oil to the oil seal lips.
3. Install a new O-ring.
INSPECTION
^ Check each component for scratches, damage and other faults.
^ Measure the backlash, and then adjust it within specification.
ADJUSTMENT
1. Using the ST, screw-in the retainer until light contact is felt.
NOTE: Screw-in the RH side slightly deeper than the LH side.
ST 18630AA010 WRENCH ASSY
2. Remove the oil pump cover.
3. Remove the liquid gasket from the mating surface completely.
4. Install the oil pump cover to converter case, and secure them with tightening four bolts evenly.
NOTE: Use an old gasket or aluminum washer so as not to damage the mating surface of housing.
Tightening torque: 41 Nm (4.2 kgf-cm, 30.4 ft. lbs.)
5. Rotate the drive pinion ten times or more using ST1 and ST2.
ST1 18667AA010 HOLDER
ST2 499787700 WRENCH
6. Tighten the retainer LH until contact is felt while rotating the shaft. Then loosen the retainer RH. Keep tightening the retainer LH, and loosening the retainer RH until the pinion shaft cannot be turned. This is the zero state.
7. After the zero state is established, back off the retainer LH 3 notches and secure it with the lock plate. Then back off the retainer RH and retighten until it stops. Rotate the drive pinion few times. Tighten the retainer RH 1-3/4 notches further. This sets the preload. Finally, secure the retainer with its lock plate.
NOTE: Turning the retainer by one tooth changes the backlash about 0.05 mm (0.0020 inch).
8. Turn the drive pinion several times with ST1 and check to see if the backlash is within the specified value with ST2, ST3, ST4 and ST5.
ST1 499787700 WRENCH
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
ST4 499787500 ADAPTER
ST5 498255400 PLATE
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
9. Adjust the tooth contact between front differential and drive shaft.