Subaru Legacy (2005 year). Manual - part 732

DI-35

DIFFERENTIALS

Rear Differential (T-type)

16) Remove the front oil seal from differential carri-
er using ST.
ST

398527700

PULLER ASSY

17) Remove the pilot bearing together with front
bearing cone and collar using ST.
ST

398467700

DRIFT

18) When replacing the bearings, hit out the front
bearing cup and rear bearing cup in this order using
a brass bar.

D: ASSEMBLY

NOTE:
• Assemble in the reverse order of disassembly.
• Check and adjust each part during assembly.
• Keep the shims and washers in order, so that
they are not improperly installed.
• Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
• Apply gear oil to the bearings and thrust washers
when installing them.
• Be careful not to mix up the bearing races RH
and LH.
• Use new O-rings and gasket.
• Replace the oil seals with new ones at every dis-
assembly. Apply grease to the lips when installing
the oil seals.
• Be careful not to mix up the differential oil seal
RH and LH.

1) Adjusting preload for front and rear bearings:
Adjust the bearing preload with collar and washer
between front and rear bearings. Pinion height ad-
justing washer are not affected by this adjustment.
The adjustment must be carried out without oil seal
inserted. 

(1) Press the rear bearing race into differential
carrier with ST1 and ST2.

ST1

398477701

HANDLE

ST2

398477703

DRIFT 2

(2) Install the front bearing race to differential
carrier using ST1 and ST2.

ST1

398477701

HANDLE

ST2

398477702

DRIFT

(A) Differential carrier

(B) Front oil seal

(A) Pilot bearing

(B) Collar

(C) Front bearing

(D) Rear bearing cup

(A) 2 cutouts along diagonal lines

(B) Hit out alternately with brass bar

(B)

(A)

DI-00145

ST

(B)

(A)

(C)

(D)

DI-00076

(B)

(A)

DI-00077

DI-00463

ST2

ST1

DI-00079

DI-36

DIFFERENTIALS

Rear Differential (T-type)

(3) Measure and record the thickness of pinion
height adjust washer.

NOTE:
If tooth contact (drive pinion, hypoid driven gear) is
normal in the inspection before disassembling, ver-
ify that the washer is not deformed, and then re-use
the used washer.

(4) Insert the ST1 into carrier with pinion height
adjusting washer and rear bearing cone fitted
onto it.

NOTE:
Use new rear bearing cone.

(5) Install the preload adjusting collar and
washer, front bearing cone, ST2, companion
flange, and washer and drive pinion nut.

ST1

398507702

DUMMY SHAFT

ST2

398507703

DUMMY COLLAR

(6) Turn the ST1 with hand to make it seated,
and tighten the self-locking nut while measuring
the preload with spring balance. Select the pre-
load adjusting washer and collar so that the
specified preload is obtained when nut is tight-
ened to the specified torque.

NOTE:
• Use a new self-locking nut.
• Be careful not to give excessive preload.
• When tightening the self-locking nut, lock ST1
with ST2 as shown in the figure.

• Measure the preload in direction of tangent to
flange.
ST1

398507702

DUMMY SHAFT

ST2

398507704

BLOCK

Tightening torque:

181 N

⋅

m (18.5 kgf-m, 134 ft-lb)

(A) Pinion height adjusting washer

(B) Preload adjusting collar

(C) Preload adjusting washer

(B)

(A)

(C)

ST2

ST1

DI-00080

DI-00117

Drive pinion bearing preload

18.1 — 38.8 N (1.8 — 4.0 kgf, 4.1 — 8.7 lbf)
at companion flange bolt hole

Preload adjust-
ing washer

Part No.

Thickness mm (in)

383705200

2.59 (0.1020)

383715200

2.57 (0.1012)

383725200

2.55 (0.1004)

383735200

2.53 (0.0996)

383745200

2.51 (0.0988)

383755200

2.49 (0.0980)

383765200

2.47 (0.0972)

383775200

2.45 (0.0965)

383785200

2.43 (0.0957)

383795200

2.41 (0.0949)

383805200

2.39 (0.0941)

383815200

2.37 (0.0933)

383825200

2.35 (0.0925)

383835200

2.33 (0.0917)

383845200

2.31 (0.0909)

ST1

ST2

DI-00081

DI-00117

DI-37

DIFFERENTIALS

Rear Differential (T-type)

2) Adjusting drive pinion height:
Adjust the drive pinion height with washer installed
between the rear bearing cone and the back of pin-
ion gear.

(1) Install the ST2.

ST1

398507702

DUMMY SHAFT

ST2

398507701

DIFFERENTIAL CARRIER 
GAUGE

ST3

398507703

DUMMY COLLAR

(2) Measure the clearance N between the end
of ST2 and the end surface of ST1 by using a
thickness gauge.

NOTE:
Make sure there is no clearance between the case
and ST2.
ST1

398507702

DUMMY SHAFT

ST2

398507701

DIFFERENTIAL CARRIER 
GAUGE

(3) Obtain the thickness of pinion height adjust-
ing washer to be inserted from the following for-
mula, and replace the temporarily installed
washer with this one.
T = To + N 

− (H × 0.01) − 0.20 mm

NOTE:
Use copies of this page.

(Example of calculation)
To = 2.20 + 1.20 = 3.40 mm
N = 0.23 mm H = + 1
T = 3.40 + 0.23 

− 0.01 − 0.20 = 3.42

Result: Thickness = 3.42 mm
Therefore use the pinion height adjusting wash-
er of part number 383605200. 

Preload adjust-
ing collar

Part No.

Length mm (in)

383695201

56.2 (2.213)

383695202

56.4 (2.220)

383695203

56.6 (2.228)

383695204

56.8 (2.236)

383695205

57.0 (2.244)

383695206

57.2 (2.252)

(A) Pinion height adjusting washer

RH

LH

N

(A)

ST2

ST3

ST1

DI-00083

ST2

ST1

DI-00084

T

Thickness of pinion height adjusting 
washer mm (in)

To

Thickness of washer temporally 
inserted mm (in)

N

Clearance of thickness gauge mm (in)

H

Figure marked on drive pinion head

Memo:

Pinion height adjusting washer

Part No.

Thickness mm (in)

383495200

3.09 (0.1217)

383505200

3.12 (0.1228)

383515200

3.15 (0.1240)

383525200

3.18 (0.1252)

383535200

3.21 (0.1264)

383545200

3.24 (0.1276)

383555200

3.27 (0.1287)

383565200

3.30 (0.1299)

383575200

3.33 (0.1311)

383585200

3.36 (0.1323)

383595200

3.39 (0.1335)

383605200

3.42 (0.1346)

383615200

3.45 (0.1358)

383625200

3.48 (0.1370)

383635200

3.51 (0.1382)

383645200

3.54 (0.1394)

383655200

3.57 (0.1406)

383665200

3.60 (0.1417)

383675200

3.63 (0.1429)

383685200

3.66 (0.1441)

DI-38

DIFFERENTIALS

Rear Differential (T-type)

3) Install the selected pinion height adjusting wash-
er on drive pinion, and press the rear bearing cone
into position with ST.
ST

398177700

INSTALLER

4) Insert the drive pinion into differential carrier, in-
stall the selected bearing preload adjusting collar
and washer.

5) Press-fit the front bearing cone into case with
ST1, ST2 and ST3.
ST1

398507703

DUMMY COLLAR

ST2

399780104

WEIGHT

ST3

899580100

INSTALLER

6) Insert the collar, then press-fit the pilot bearing
with ST1 and ST2.
ST1

399780104

WEIGHT

ST2

899580100

INSTALLER

7) Fit a new oil seal using ST.

NOTE:
• Press-fit until end of oil seal is 1 mm (0.04 in) in-
ward from end of carrier.
• Apply grease to the oil seal lips.
ST

498447120

INSTALLER

8) Press-fit the companion flange with ST1 and
ST2.

NOTE:
Be careful not to damage the bearing.
ST1

899874100

INSTALLER

ST2

399780104

WEIGHT

(A) Drive pinion

(B) Bearing preload adjusting collar

(C) Bearing preload adjusting washer

(D) Differential carrier

ST

DI-00085

(A)

(B)

(C)

(D)

DI-00086

ST3

ST1

ST2

DI-00087

ST2

ST1

DI-00088

ST

DI-00089

ST1

ST2

DI-00090