Subaru Legacy III (2000-2003 year). Manual - part 558

AT-126

AUTOMATIC TRANSMISSION

FRONT DIFFERENTIAL

2. SIDE RETAINER

NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
1) Remove O-ring.

2) Remove oil seal.

3) Take out either split pin, remove claw.
ST

398527700

PULLER ASSY

4) Securely attach two claws to outer race, set ST
to side retainer.

ST

398527700

PULLER ASSY

5) Return removed claw to the original position,
and install pin and split pin. 
6) Hold the shaft of ST to avoid removing from side
retainer, and then remove the bearing outer race.
ST

398527700

PULLER ASSY

NOTE:
Replace bearing inner and outer races as a single
unit.

(A) Claw

(B) Split pin

(C) Pin

AT-00219

AT-00220

AT-00221

ST

( A )

( B )

( C )

(A) Shaft

(B) Claw

(A) Shaft

(B) Side retainer

AT-00222

( A )

( B )

ST

AT-00223

ST

( B )

( A )

AT-127

AUTOMATIC TRANSMISSION

FRONT DIFFERENTIAL

D: ASSEMBLY

1. DIFFERENTIAL CASE ASSEMBLY

1) Install the washer, differential bevel gear and dif-
ferential bevel pinion in the differential case (RH).
Insert the pinion shaft.
2) Install straight pin from reverse direction.

3) Install the washer and differential bevel gear to
the differential case (LH). Then put the case over
the differential case (RH), and connect both cases.
4) Install the crown gear and secure by tightening
the bolt.

Standard tightening torque:

62 N·m (6.3 kgf-m, 45.6 ft-lb)

5) Measurement of backlash (Selection of washer)

(1) Measure the gear backlash with ST1 and
ST2, and insert ST2 through the access window
of the case.

ST1

498247001

MAGNET BASE

ST2

498247100

DIAL GAUGE

NOTE:
• Measure the backlash by applying a pinion tooth
between two bevel gear teeth.
• Fix bevel pinion gear in place with a screwdriver
or similar tool when measuring. 

Standard value:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

(2) If backlash is not as specified, select a
washer from the table below.

6) Using ST, install taper roller bearing.
ST

398437700

DRIFT

2. SIDE RETAINER

1) Install bearing outer race to side retainer.
2) Install a new oil seal using the ST and hammer.
ST

499797000

INSTALLER

(A) Differential case (RH)

(A) Crown gear

(B) Differential case (RH)

(C) Differential case (LH)

AT-00218

( A )

AT-00217

( A )

( B )

( C )

Washer

Part No.

Thickness mm (in)

803038021

0.95 (0.037)

803038022

1.00 (0.039)

803038023

1.05 (0.041)

(A) Taper roller bearing

AT-00224

ST2

ST1

AT-00225

( A )

ST

AT-00711

ST

AT-128

AUTOMATIC TRANSMISSION

FRONT DIFFERENTIAL

3) Install new O-ring.

E: INSPECTION

• Check each component for harmful cuts, dam-
age and other faults.
• Measure the backlash and adjust to within spec-
ifications.
<Ref. to AT-128, ADJUSTMENT, Front Differen-
tial.>

F: ADJUSTMENT

1) Using ST, screw in the retainer until light contact
is felt.

NOTE:
Screw in the RH side slightly deeper than the LH
side.
ST

499787000 WRENCH 

ASSY

2) Remove the oil pump housing.
3) Thoroughly remove the liquid gasket from the
case mating surface beforehand.
4) Install the oil pump housing assembly to the
torque converter clutch case, and secure evenly by
tightening four bolts.

NOTE:
Use an old gasket or an aluminum washer so as not
to damage the mating surface of the housing.

Tightening torque:

41 N·m (4.2 kgf-m, 30.4 ft-lb)

AT-00219

AT-00227

ST

AT-00205

AT-129

AUTOMATIC TRANSMISSION

FRONT DIFFERENTIAL

5) Rotate the drive pinion several times with ST1
and ST2.
ST1

498937110

HOLDER

ST2

499787700

WRENCH

6) Tighten the LH retainer until contact is felt while
rotating the shaft. Then loosen the RH retainer.
Keep tightening the LH retainer and loosening the
RH retainer until the pinion shaft can no longer be
turned. This is the “zero” state.

7) After the “zero” state is established, back off the
LH retainer 3 notches and secure it with the lock
plate. Then back off the RH retainer and retighten
until it stops. Rotate drive pinion a few times. Tight-
en the RH retainer 1-3/4 notches further. This sets
the preload. Finally, secure the retainer with its lock
plate.

NOTE:
Turning the retainer by one tooth changes the
backlash about 0.05 mm (0.0020 in).

8) Turn the drive pinion several rotations with ST1
and check to see if the backlash is within the stan-
dard value with ST2, ST3, ST4 and ST5.
ST1

499787700

WRENCH

ST2

498247001

MAGNET BASE

ST3

498247100

DIAL GAUGE

ST4

499787500

ADAPTER

ST5

498255400

PLATE

Backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

9) Adjust the tooth contact between front differen-
tial and drive shaft. <Ref. to AT-121, ADJUST-
MENT, Drive Pinion Shaft.>

(A) Retainer

(A) Lock plate

AT-00206

ST1

ST2

AT-00229

( A )

AT-00214

( A )

0.05 mm
(0.0020 in)

AT-00230

AT-00231

ST1

ST4

ST5

ST2

ST3