Subaru Legacy (2005 year). Manual - part 740

DI-67

DIFFERENTIALS

Rear Differential (VA-type)

(2) Install the bearing race into holder RH and
LH.

ST

398417700

DRIFT PUNCH

CAUTION:
Make sure that the oil seal, bearing outer race 
and cone are properly assembled.

(3) Install the differential assembly into differen-
tial carrier in the reverse order of disassembly.

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

(4) Temporally tighten the side holder RH and
LH in differential carrier to install.

13) Perform the backlash adjustment between the
hypoid driven gear and drive pinion, and preload
adjustment of differential side bearing.

(1) Turn the drive pinion with ST for better fitting
of differential side bearing.

ST

498427200

FLANGE WRENCH

(2) Screw in the side holder LH until light con-
tact is made with ST.

ST

18630AA010

WRENCH ASSY

(3) Back off the side (hypoid driven gear side)
holder approx.1 1/2 teeth of holder, and tighten
the other side holder by approx. 2 teeth (approx.
1 1/2 + 1/2 teeth). [Back off amount of side (hy-
poid driven gear side) holder + 1/2 tooth.]
This + 1/2 tooth gives preload.
(4) Temporarily tighten the lock plate.

NOTE:
Turn over the lock plate to displace the holder 1/2
tooth.

(5) Measure the hypoid driven gear-to-drive
pinion backlash. Set the magnet base on differ-
ential carrier. Align the contact point of dial
gauge with tooth face of hypoid driven gear, and
move hypoid driven gear while holding drive pin-
ion still. Read the value indicated on dial gauge.

NOTE:
If measured backlash is not within specified range,
repeat the procedures for pinion driven gear set
backlash adjustment and differential side bearing
preload adjustment.

Backlash:

0.10 — 0.15 mm (0.0039 — 0.0059 in)

DI-00366

DI-00385

ST

ST

DI-00399

DI-00364

DI-00172

DI-68

DIFFERENTIALS

Rear Differential (VA-type)

14) Draw a matching mark on both differential car-
rier and holder. Remove the holder side at a time.
Replace in the original position after inserting an O-
ring and applying grease to threaded portion.

15) Tighten the bolt of lock plate to specified
torque.

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

16) Recheck the hypoid driven gear to pinion back-
lash.

Backlash:

0.10 — 0.15 mm (0.0039 — 0.0059 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.]

• Face contact

Checking item: Backlash is too large.
Contact pattern

(A) Alignment mark

(B) Holder

DI-00386

(B)

(A)

DI-00364

DI-00172

(A) Toe side

(B) Heel side

AT-00207

(A)

(B)

AT-00208

DI-69

DIFFERENTIALS

Rear Differential (VA-type)

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.

18) If proper tooth contact is not obtained, once
again adjust the drive pinion height and the differ-
ential side bearing preload (already mentioned)
and the hypoid gear backlash.

AT-00212

AT-00209

AT-00213

AT-00210

AT-00213

AT-00211

AT-00212

DI-70

DIFFERENTIALS

Rear Differential (VA-type)

19) Install the new gasket and rear cover to differ-
ential carrier and tighten the bolts to specified
torque.

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

E: INSPECTION

Wash all the disassembled parts clean, and exam-
ine them for wear, damage and other defects. Re-
pair or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
• If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact. Re-
place the gear if excessively worn or incapable of
adjustment.
• If crack, score or seizure is evident, replace as a
set. Slight damage of tooth can be corrected by oil
stone or the like.
2) Side gear and pinion mate gear
• Replace if crack, score or other defects are evi-
dent on tooth surface.
• Replace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearings
Replace if seizure, peeling, wear, rust, dragging
during rotation, noise or other defect is evident.
4) Thrust washers of side gear and pinion mate
gear:
Replace if seizure, flaw, abnormal wear or other
defect is evident.
5) Oil seal
Replace if deformed or damaged, and at every dis-
assembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal lip contacting surfaces have
flaws.

1. SIDE GEAR BACKLASH

Using a dial gauge, check the backlash of the side
gear. (VA1-type only)

Side gear backlash:

0.05 — 0.15 mm (0.0020 — 0.0059 in)

If the side gear backlash is not within the specifica-
tion, adjust it as specified by selecting side gear
thrust washer.

2. HYPOID DRIVEN GEAR BACKLASH

Using a dial gauge, check the backlash of hypoid
driven gear.

Hypoid driven gear backlash:

0.10 — 0.15 mm (0.0039 — 0.0059 in)

If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or re-
pair if necessary.

3. TOOTH CONTACT BETWEEN HYPOID 
DRIVEN GEAR AND DRIVE PINION

Inspect the tooth contact between hypoid driven
gear and drive pinion. <Ref. to DI-55, ASSEMBLY,
Rear Differential (VA-type).>

DI-00387

DI-00240

DI-00099