Subaru Legacy (2005 year). Manual - part 733

DI-39

DIFFERENTIALS

Rear Differential (T-type)

9) Install a new self-locking nut and secure the
companion flange using ST and tighten the nut.
ST

498427200

FLANGE WRENCH

Tightening torque:

181 N

⋅

m (18.5 kgf-m, 134 ft-lb)

10) Assembling differential case
Install the side gears and pinion mate gears, with
their thrust washers and pinion mate shaft, into dif-
ferential case. (Model without LSD)

NOTE:
• Apply gear oil on both sides of the washer and on
the side gear shaft before installing.
• Insert the pinion mate shaft into the differential
case by aligning the lock pin holes.

(1) Measure the side gear backlash.

Side gear backlash:

0.10 — 0.20 mm (0.0039 — 0.0079 in)

(2) Adjust the side gear backlash as specified
by selecting side gear thrust washer.

(3) Check the condition of rotation after apply-
ing oil to the gear tooth surfaces and thrust sur-
faces.
(4) After inserting the pinion shaft lock pin into
differential case, stake the both sides of the hole
to prevent pin from falling off.

11) Install the hypoid driven gear to differential
case.

NOTE:
• Before installing bolts, apply Lock Tite to bolt
threads.

Lock Tite:

THREE BOND 1324 (Part No. 004403042)

• Tighten diagonally while tapping the bolt heads.

Tightening torque:

105 N

⋅

m (10.7 kgf-m, 77.4 ft-lb)

ST

DI-00091

DI-00239

Side gear thrust washer

Part No.

Thickness mm (in)

383445201

0.75 — 0.80 (0.0295 — 0.0315)

383445202

0.80 — 0.85 (0.0315 — 0.0335)

383445203

0.85 — 0.90 (0.0335 — 0.0354)

DI-00240

DI-00068

S303.fm  39 ページ  ２００７年１２月３日　月曜日　午後１時４４分

DI-40

DIFFERENTIALS

Rear Differential (T-type)

12) Press the side bearing into differential case us-
ing ST.
ST

398487700

DRIFT

13) Press-fit the side bearing cone to the side bear-
ing retainer using ST.
ST

398417700

DRIFT PUNCH

14) Adjusting the side bearing retainer shims

(1) The hypoid driven gear backlash and side
bearing preload can be adjusted by the side
bearing retainer shim thickness.
(2) Install the differential assembly into differen-
tial carrier in the reverse order of disassembly.

NOTE:
Be careful not to hit the teeth against the cace.

(3) Install the side bearing retainer shims to re-
tainers RH and LH from which they were re-
moved.

NOTE:
Replace the broken or corroded side retainer shim
with a new one of same thickness.

(4) Align the arrow mark on differential carrier
with the mark on side retainer during installation.

NOTE:
Be careful that side bearing outer race is not dam-
aged by bearing roller.

(5) Tighten the side bearing retainer bolts.

Tightening torque:

10.3 N

⋅

m (1.05 kgf-m, 7.6 ft-lb)

ST

DI-00095

DI-00324

ST

DI-00065

Side bearing retainer shim

Part No.

Thickness mm (in)

383475201

0.20 (0.0079)

383475202

0.25 (0.0098)

383475203

0.30 (0.0118)

383475204

0.40 (0.0157)

383475205

0.50 (0.0197)

(A) Arrow mark

(A)

DI-00097

DI-00098

DI-41

DIFFERENTIALS

Rear Differential (T-type)

(6) Measure the hypoid driven gear to drive pin-
ion backlash. Set the magnet base on differen-
tial carrier. Align the contact point of dial gauge
with tooth face of hypoid driven gear, and move
hypoid driven gear while holding drive pinion
still. Read the value indicated on dial gauge. If
the backlash exceeds 0.2 mm (0.08 in), reduce
the thickness of shim on the back face of hypoid
driven gear and increase the thickness of shim
on the tooth face of hypoid driven gear. If the
backlash is less than 0.1 mm (0.004 in), in-
crease the thickness of shim on the back face of
hypoid driven gear and reduce the thickness of
shim on the tooth face of hypoid driven gear.

Backlash:

0.10 — 0.20 mm (0.0039 — 0.0079 in)

(7) At the same time, measure the total preload
of drive pinion. Compared with the resistance
when differential case is not installed, if the total
preload is not within specification, adjust the
thickness of side bearing retainer shims, in-
creasing/reducing by an even amount at a time.

Total preload:

20.7 — 54.4 N (2.1 — 5.5 kgf, 4.7 — 12.2 lbf)

15) Recheck the hypoid driven gear to drive pinion
backlash.

Backlash:

0.10 — 0.20 mm (0.0039 — 0.0079 in)

16) Check the hypoid driven gear runout on its
back surface, and make sure that pinion and hy-
poid driven gear rotates smoothly.
If the hypoid driven gear runout on its back surface
exceed the specification, verify that there is any for-
eign material between hypoid driven gear and dif-
ferential case, and they are not deformed.

Hypoid driven gear runout on its back surface:

0.05 mm (0.0020 in)

17) Checking and adjusting the tooth contact of hy-
poid driven gear

(1) Apply an even coat of red lead on both sides
of three or four teeth on the hypoid driven gear.
Check the contact pattern after rotating the hy-
poid driven gear several revolutions back and
forth until a definite contact pattern appears on
the hypoid driven gear.
(2) When the contact pattern is incorrect, read-
just.

NOTE:
Be sure to wipe off red lead completely after adjust-
ment is completed.

• Correct tooth contact

Checking item: Tooth contact pattern is slightly
shifted toward toe side under no-load rotation.
[When loaded, contact pattern moves toward
heel.]

DI-00099

DI-00099

(A) Toe side

(B) Heel side

DI-00101

AT-00207

(A)

(B)

DI-42

DIFFERENTIALS

Rear Differential (T-type)

• Face contact

Checking item: Backlash is too large.
Contact pattern

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

• Flank contact

Checking item: Backlash is too small.
Contact pattern

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

• Toe contact (inside end contact)

Checking item: Contact areas is small
Contact pattern

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

• Heel contact (outside end contact)

Checking item: Contact areas is small
Contact pattern

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

AT-00208

AT-00212

AT-00209

AT-00213

AT-00210

AT-00213

AT-00211

AT-00212