Subaru Legacy (2005 year). Manual - part 534

4AT-117

AUTOMATIC TRANSMISSION

Front Differential Assembly

2. 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) Attach 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 sin-
gle unit.

(A) Claw

(B) Split pin

(C) Pin

AT-00219

AT-00220

AT-00221

(A) Shaft

(B) Claw

(A) Shaft

(B) Side retainer

AT-00222

AT-00223

4AT-118

AUTOMATIC TRANSMISSION

Front Differential Assembly

D: ASSEMBLY

1. DIFFERENTIAL CASE ASSEMBLY

1) Install the washer, differential bevel gear and dif-
ferential 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 both cases.
4) Install the hypoid driven gear and secure by
tightening the bolt.

Tightening torque:

62 N

⋅

m (6.3 kgf-m, 45.6 ft-lb)

5) Measurement of backlash (Selection of washer)

(1) Install the SUBARU genuine axle shaft to
differential case.

Parts No. 38415AA070 AXLE SHAFT

(2) Measure the gear backlash using ST1 and
ST2, and then insert the ST2 though 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 screw-
driver or similar tool when measuring.

Specification:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

(3) If the backlash is not within specified, select
a washer from the table below.

6) Using the ST, install the taper roller bearing.
ST

398487700

INSTALLER

(A) Differential case (RH)

(A) Hypoid driven gear

(B) Differential case (RH)

(C) Differential case (LH)

AT-00218

(A)

(B)

AT-00217

(A)

(C)

Washer

Part No.

Thickness mm (in)

803038021

0.95 (0.037)

803038022

1.00 (0.039)

803038023

1.05 (0.041)

(A) Taper roller bearing

AT-00224

ST2

ST1

AT-00225

4AT-119

AUTOMATIC TRANSMISSION

Front Differential Assembly

2. SIDE RETAINER

1) Install the bearing outer race to side retainer.
2) Install a new oil seal using ST and hammer.
ST

18675AA000

DIFFERENTIAL SIDE OIL 
SEAL INSTALLER

3) Apply gear oil to new O-ring and install it.

E: INSPECTION

• Check each component for scratches, damage
or other faults.
• Measure the backlash, and then adjust it within
specification.
<Ref. to 4AT-119, ADJUSTMENT, Front Differen-
tial Assembly.>

F: ADJUSTMENT

1) Using the ST, screw-in the retainer until resis-
tance is felt.

NOTE:
Screw-in the RH side slightly deeper than the LH
side.
ST

499787000

WRENCH ASSY

2) Remove the oil pump housing.

3) Remove the liquid gasket from the mating sur-
face completely.
4) Install the oil pump housing assembly to convert-
er 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 N

⋅

m (4.2 kgf-m, 30.4 ft-lb)

5) Rotate the drive pinion several times using ST1
and ST2.
ST1

498937110

HOLDER

ST2

499787700

WRENCH

6) Tighten the retainer LH by rotating the shaft until
resistance is felt. Then loosen the retainer RH.
Keep tightening the retainer LH, and loosening the
retainer RH until the pinion shaft no longer be
turned. This is to the “zero” state.

AT-00226

ST

AT-00219

AT-00227

ST

(A) Retainer

AT-00205

AT-00206

ST2

ST1

AT-00229

(A)

4AT-120

AUTOMATIC TRANSMISSION

Front Differential Assembly

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 two to three
times. Tighten the retainer RH further 1-3/4 notch-
es. This sets the preload. Finally, secure the retain-
er with its lock plate.

NOTE:
Turning the retainer by one tooth changes the
backlash approx. 0.05 mm (0.0020 in).

8) Install the axle shaft of part to both side of front
differential part.
Parts No. 38415AA000 AXLE SHAFT
9) Turn the drive pinion several times using ST1,
and check to see if the backlash is within the spec-
ification using 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 in)

10) Adjust the tooth contact between front differen-
tial and drive shaft. <Ref. to 4AT-112, ADJUST-
MENT, Drive Pinion Shaft Assembly.>

(A) Lock plate

AT-00214

(A)

0.05 mm
(0.0020 in)

AT-00230

AT-00231

ST5

ST3

ST2

ST1

ST4