Subaru Legacy (2005 year). Manual - part 739

DI-63

DIFFERENTIALS

Rear Differential (VA-type)

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

398477703

DRIFT 2

(2) Using the ST, install the front bearing race to
the differential carrier.

ST

499277200

INSTALLER

(3) Insert the front bearing cone.

NOTE:
Use new front bearing cone.

(4) Measure and record the thickness of pinion
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 carrier 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, collar, companion
flange, and washer and self-locking nut.

ST1

18678AA000 DUMMY SHAFT

(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.

NOTE:
• Use a new self-locking nut.
• Be careful not to give excessive preload.
• When tightening the self-locking nut, lock com-
panion flange using ST2 as shown in the figure.
• Measure the preload in direction of tangent to
flange.
ST1

18678AA000 DUMMY SHAFT

ST2

498427200

FLANGE WRENCH

DI-00375

ST2

ST1

DI-00376

ST

(A) Pinion height adjusting washer

(B) Preload adjusting collar

(C) Preload adjusting washer

(D) Collar

ST1

DI-00377

(D)

(C)

(B)

(A)

DI-00152

DI-64

DIFFERENTIALS

Rear Differential (VA-type)

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

18678AA000 DUMMY SHAFT

ST2

18831AA010 DIFFERENTIAL CARRIER 

GAUGE

(2) Install the side holder LH to the left side of
differential carrier in reverse direction.

(3) 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

18678AA000 DUMMY SHAFT

ST2

18831AA010 DIFFERENTIAL CARRIER 

GAUGE

Drive pinion bearing preload

12.7 — 32.4 N (1.3 — 3.3 kgf, 2.9 — 7.3 lbf)
(at companion flange bolt hole)

Preload adjusting 
washer

Part No.

Thickness mm (in)

38336AA430

1.500 (0.0591)

38336AA440

1.513 (0.0596)

38336AA450

1.525 (0.0600)

38336AA460

1.538 (0.0606)

38336AA470

1.550 (0.0610)

38336AA480

1.563 (0.0615)

38336AA490

1.575 (0.0620)

38336AA500

1.588 (0.0625)

38336AA510

1.600 (0.0630)

38336AA520

1.613 (0.0635)

38336AA530

1.625 (0.0640)

38336AA540

1.638 (0.0645)

38336AA550

1.650 (0.0650)

38336AA560

1.663 (0.0655)

38336AA570

1.675 (0.0659)

38336AA580

1.688 (0.0665)

38336AA590

1.700 (0.0669)

38336AA600

1.713 (0.0674)

38336AA610

1.725 (0.0679)

38336AA620

1.738 (0.0684)

38336AA630

1.750 (0.0689)

38336AA640

1.763 (0.0694)

38336AA650

1.775 (0.0699)

Preload adjusting 
collar

Part No.

Length mm (in)

31454AA250

51.05 (2.010)

31454AA260

51.25 (2.018)

31454AA270

51.35 (2.022)

31454AA280

51.45 (2.026)

31454AA290

51.55 (2.030)

31454AA300

51.65 (2.033)

31454AA310

51.75 (2.037)

31454AA320

51.85 (2.041)

31454AA330

52.05 (2.049)

DI-00398

ST2

(A) Pinion height adjusting washer

RH

LH

N

(A)

ST2

ST1

DI-00379

DI-00380

DI-00381

ST2

ST1

DI-65

DIFFERENTIALS

Rear Differential (VA-type)

(4) 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 32295AA370.

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

398177700

INSTALLER

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

5) Set ST and differential carrier to the press and
install the front bearing cone.
ST

399780104

WEIGHT

NOTE:
Set the carrier to the press until the companion
flange is installed.
6) Insert the collar, then install the pilot bearing.

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)

32295AA350

0.150 (0.0059)

32295AA360

0.175 (0.0069)

32295AA370

0.200 (0.0079)

32295AA380

0.225 (0.0089)

32295AA390

0.250 (0.0098)

32295AA400

0.275 (0.0108)

ST

DI-00085

(A) Drive pinion

(B) Bearing preload adjusting collar

(C) Bearing preload adjusting washer

(D) Differential carrier

(A) Pilot bearing

(B) Collar

(D)

(A)

(B)

(C)

DI-00382

ST

DI-00383

DI-00389

(A)

(B)

DI-66

DIFFERENTIALS

Rear Differential (VA-type)

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

499277200

INSTALLER

8) Press-fit the companion flange using ST.

NOTE:
Be careful not to damage the bearing.
ST

899874100

INSTALLER

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) Install the hypoid driven gear on differential
case.

NOTE:
• Tighten diagonally while tapping the bolt heads.
• Set a cushioning such as wooden block, alumi-
num plate or shop cloth between vise and differen-
tial case if the side gear comes into contact with
vise.

Tightening torque:

62 N

⋅

m (6.3 kgf-m, 45.6 ft-lb)

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

398487700

DRIFT

12) Assemble holders.

(1) Install the new oil seal into holder RH and
LH.

ST

498447100

INSTALLER

ST

DI-00089

DI-00384

ST

DI-00372

ST

DI-00371

ST

DI-00095

ST

DI-00166