Subaru Legacy (2005 year). Manual - part 660

5MT-87

MANUAL TRANSMISSION AND DIFFERENTIAL

Front Differential Assembly

5) Install the hypoid driven gear to differential case
using twelve bolts.

Tightening torque:

T: 62 N

⋅

m (6.3 kgf-m, 45.6 ft-lb)

2. SIDE RETAINER

1) Install a new oil seal.
ST

18675AA000

DIFFERENTIAL SIDE OIL 
SEAL INSTALLER

NOTE:
• For press-fitting of oil seal to retainer, make tap-
ping with plastic hammer etc.
• Do not use press.
2) Install a new O-ring.

NOTE:
Do not stretch or damage the O-ring.

E: INSPECTION

Repair or replace the differential gear in following
cases:
• When the hypoid drive gear and drive pinion
shaft tooth surface are damaged, excessively worn
or seized.
• When the roller bearing on the drive pinion shaft
is worn or damaged.
• When there is damage, wear or seizure of the dif-
ferential bevel pinion, differential bevel gear, wash-
er, pinion shaft and straight pin.
• When the differential case sliding surfaces is
worn or damaged.

(A) Hypoid driven gear

(B) Differential case

MT-00993

(B)

(A)

T

MT-00289

ST

MT-00279

(A) Drive pinion shaft

(B) Hypoid driven gear

(C) Pinion shaft

(D) Straight pin

(E) Washer

(F) Differential bevel gear

(G) Differential bevel pinion

(H) Roller bearing

(I) Differential case

MT-00291

(A)

(B)

(C)

(E)

(E)

(F)

(F)

(G)

(G)

(D)

(H)

(I)

(H)

5MT-88

MANUAL TRANSMISSION AND DIFFERENTIAL

Front Differential Assembly

1. BEVEL PINION GEAR BACKLASH

Measure the backlash between bevel gear and pin-
ion. If it is not within specification, install a suitable
washer to adjust.

NOTE:
Be sure the pinion gear teeth contacts adjacent
gear teeth during measurement.
ST1

498247001

MAGNET BASE

ST2

498247100

DIAL GAUGE

Standard backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

2. HYPOID GEAR BACKLASH

1) Set the ST1, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface on
the right corner and check the backlash.
ST1

498247001

MAGNET BASE

ST2

498247100

DIAL GAUGE

ST3

498255400

PLATE

2) Install the SUBARU genuine axle shafts to both
side, rotate in the inversion direction so that the
gauge contact with the tooth surface and read the
dial gauge.
Part No. 38415AA100AXLE SHAFT

Backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

NOTE:
If the backlash is outside the specified range, ad-
just it by turning the side retainer in right side case.

3. TOOTH CONTACT OF HYPOID GEAR

Check tooth contact of hypoid gear as follows: Ap-
ply a uniform thin coat of red lead on both tooth sur-
faces of 3 or 4 teeth of the hypoid gear. Move the
hypoid gear back and forth by turning the transmis-
sion main shaft until a definite contact pattern is de-
veloped on hypoid gear, and judge whether face
contact is correct. If it is inaccurate, make adjust-
ment. <Ref. to 5MT-88, ADJUSTMENT, Front Dif-
ferential Assembly.>
• Tooth contact is correct.

F: ADJUSTMENT

1. BEVEL PINION GEAR BACKLASH

1) Disassemble the front differential. <Ref. to 5MT-
84, REMOVAL, Front Differential Assembly.>
2) Select a different washer from the table and in-
stall.

3) Adjust until the standard is obtained.

Backlash:

Standard

0.13 — 0.18 mm (0.0051 — 0.0071 in)

MT-00285

ST1

ST2

MT-00293

ST1

ST2

ST3

(A) Toe

(B) Coast side

(C) Heel

(D) Drive side

Washer

Part Number

Thickness mm (in)

803038021

0.925 — 0.950

(0.0364 — 0.0374)

803038022

0.975 — 1.000

(0.0384 — 0.0394)

803038023

1.025 — 1.050

(0.0404 — 0.0413)

MT-00294

(A)

(B)

(C)

(D)

5MT-89

MANUAL TRANSMISSION AND DIFFERENTIAL

Front Differential Assembly

2. HYPOID GEAR BACKLASH

Adjust the backlash by turning holder in the right
side case.
ST

499787000

WRENCH ASSY

NOTE:
Each time the side retainer rotates one notch,
backlash changes by 0.05 mm (0.020 in).

3. TOOTH CONTACT OF HYPOID GEAR

1) Adjust until correct teeth contact is obtained.
2) Check tooth contact as follows.
• Tooth contact
Checking item: Tooth contact pattern is slightly
shifted to toe side under no-load rotation.
[When loaded, contact pattern moves toward
heel.]

• Face contact
Checking item: Backlash is too large.
Contact pattern

Corrective action: Reduce thickness of pinion
height adjusting washer in order to bring drive pin-
ion closer to driven gear.

• Flank contact
Checking item: Backlash is too small.
Contact pattern

Corrective action: Increase thickness of pinion
height adjusting washer in order to bring drive pin-
ion away from driven gear.

(A) Toe side

(B) Heel side

MT-00176

ST

MT-00296

0.05mm(0.0020 in)

AT-00207

(A)

(B)

AT-00208

AT-00212

AT-00209

AT-00213

5MT-90

MANUAL TRANSMISSION AND DIFFERENTIAL

Front Differential Assembly

• Toe contact (inside end contact)
Checking item: Contact area is small.
Contact pattern

Corrective action: Increase thickness of pinion
height adjusting washer in order to bring drive pin-
ion closer to driven gear.

• Heel contact (outside end contact)
Checking item: Contact area is small.
Contact pattern

Corrective action: Reduce thickness of pinion
height adjusting washer in order to bring drive pin-
ion away from driven gear.

AT-00210

AT-00213

AT-00211

AT-00212