Subaru Legacy (2005 year). Manual - part 737

 

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Subaru Legacy (2005 year). Manual - part 737

 

 

DI-55

DIFFERENTIALS

Rear Differential (VA-type)

D: ASSEMBLY

1. VA1-TYPE

NOTE:
• Assemble in the reverse order of disassembly.
• Check and adjust each part during assembly.
• Use a new gasket.
• 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 when installing the bearings and
thrust washers.
• Be careful not to mix up the bearing races RH
and LH.
• Replace the oil seal with a new one at every dis-
assembly. Apply grease to the lips when installing
the oil seal.
• 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) Install the rear bearing race into differential
carrier with ST1 and ST2.

ST1

398477701

HANDLE

ST2

398477702

DRIFT

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

ST1

398477701

HANDLE

ST2

498447110

DRIFT

(3) Insert the front bearing cone.

NOTE:
Use new front bearing cone.

(4) 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.

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

NOTE:
Use new rear bearing cone.

(6) Install the preload adjusting collar and
washer, front bearing cone, ST2, companion
flange, and washer and self-locking nut.

ST1

498447150

DUMMY SHAFT

ST2

32285AA000 DUMMY COLLAR

(7) 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.

DI-00463

DI-00149

ST2

ST1

(A) Pinion height adjusting washer

(B) Preload adjusting collar

(C) Preload adjusting washer

(B)

(A)

(C)

ST1

ST2

DI-00150

DI-00152

DI-56

DIFFERENTIALS

Rear Differential (VA-type)

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

498447150

DUMMY SHAFT

ST2

398507704

BLOCK

Tightening torque:

191 N

⋅

m (19.5 kgf-m, 141 ft-lb)

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

498447150

DUMMY SHAFT

ST2

498505501

DIFFERENTIAL CARRIER 
GAUGE

ST3

32285AA000 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

498447150

DUMMY SHAFT

ST2

498505501

DIFFERENTIAL CARRIER 
GAUGE

Drive pinion bearing preload

For new bearing:
12.7 — 32.2 N (1.3 — 3.3 kgf, 2.9 — 7.3 lbf)
Measure at companion flange bolt hole

Preload adjusting 
washer

Part No.

Thickness mm (in)

38336AA000

1.500 (0.0591)

38336AA120

1.513 (0.0596)

38336AA010

1.525 (0.0600)

38336AA130

1.538 (0.0606)

38336AA020

1.550 (0.0610)

38336AA140

1.563 (0.0615)

38336AA030

1.575 (0.0620)

38336AA150

1.588 (0.0625)

38336AA040

1.600 (0.0630)

38336AA160

1.613 (0.0635)

38336AA050

1.625 (0.0640)

38336AA170

1.638 (0.0645)

38336AA060

1.650 (0.0650)

38336AA180

1.663 (0.0655)

38336AA070

1.675 (0.0659)

38336AA190

1.688 (0.0665)

38336AA080

1.700 (0.0669)

38336AA200

1.713 (0.0674)

38336AA090

1.725 (0.0679)

38336AA210

1.738 (0.0684)

38336AA100

1.750 (0.0689)

38336AA220

1.763 (0.0694)

38336AA110

1.775 (0.0699)

ST1

ST2

DI-00081

Preload adjusting 
collar

Part No.

Length mm (in)

32288AA040

52.3 (2.059)

32288AA050

52.5 (2.067)

31454AA100

52.6 (2.071)

32288AA060

52.7 (2.075)

31454AA110

52.8 (2.079)

32288AA070

52.9 (2.083)

31454AA120

53.0 (2.087)

32288AA080

53.1 (2.091)

32288AA090

53.3 (2.098)

(A) Pinion height adjusting washer

RH

LH

N

(A)

ST2

ST3

ST1

DI-00083

ST2

ST1

DI-00084

DI-57

DIFFERENTIALS

Rear Differential (VA-type)

(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.

NOTE:
Adjust it using the 1 — 3 washers.
T = To + N 

− 0.05 (mm)

(Example of calculation)
To = 0.15 mm
N = 0.1 mm
T = 0.15 + 0.1 

− 0.05 = 0.2 mm

Result: Thickness = 0.2 mm
Therefore use the pinion height adjusting washer of
part number 32295AA220.

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

498175500

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 carrier using
ST1, ST2 and ST3.
ST1

32285AA000 DUMMY COLLAR

ST2

399780104

WEIGHT

ST3

899580100

INSTALLER

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

399780104

WEIGHT

ST2

899580100

INSTALLER

7) Fit a new oil seal with 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.

T

Thickness of pinion height adjusting 
washer mm (in)

To

Thickness of washer temporally 
inserted mm (in)

N

Clearance of thickness gauge mm (in)

Memo:

Pinion height adjusting washer

Part No.

Thickness mm (in)

32295AA200

0.150 (0.0059)

32295AA210

0.175 (0.0069)

32295AA220

0.200 (0.0079)

32295AA230

0.225 (0.0089)

32295AA240

0.250 (0.0098)

32295AA250

0.275 (0.0108)

ST

DI-00085

(A) Drive pinion

(B) Bearing preload adjusting collar

(C) Bearing preload adjusting washer

(D) Differential carrier

(D)

(A)

(B)

(C)

DI-00156

ST3

ST1

ST2

DI-00087

ST2

ST1

DI-00088

DI-58

DIFFERENTIALS

Rear Differential (VA-type)

ST

498447120

INSTALLER

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

NOTE:
Be careful not to damage the bearing.
ST1

899874100

INSTALLER

ST2

399780104

WEIGHT

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

498427200

FLANGE WRENCH

Tightening torque:

191 N

⋅

m (19.5 kgf-m, 141 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.

NOTE:
• Apply gear oil to both sides of the washer and 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:

0.05 — 0.15 mm (0.0020 — 0.0059 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.

ST

DI-00089

ST1

ST2

DI-00090

ST

DI-00161

Side gear thrust washer

Part No.

Thickness mm (in)

803135011

0.925 — 0.950 (0.0364 — 0.0374)

803135012

0.950 — 0.975 (0.0374 — 0.0384)

803135013

0.975 — 1.000 (0.0384 — 0.0394)

803135014

1.000 — 1.025 (0.0394 — 0.0404)

803135015

1.025 — 1.050 (0.0404 — 0.0413)

DI-00239

DI-00240

 

 

 

 

 

 

 

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