Subaru Legacy III (2000-2003 year). Manual - part 632

MT-96

MANUAL TRANSMISSION AND DIFFERENTIAL

FRONT DIFFERENTIAL ASSEMBLY

C: DISASSEMBLY

1. DIFFERENTIAL CASE ASSEMBLY

1) Remove right and left snap rings from differen-
tial, and  then remove two axle drive shafts.

NOTE:
During reassembly, reinstall each axle drive shaft
in the same place  from which it was removed.
2) Loosen twelve bolts and remove hypoid driven
gear.

3) Drive out straight pin from differential assembly
toward  hypoid driven gear.
ST

899904100

REMOVER

4) Pull out pinion shaft, and remove differential
bevel pinion and gear and washer.

5) Remove roller bearing using ST.
ST

399527700

PULLER SET

2. SIDE RETAINER

1) Remove O-ring.

(A) Hypoid driven gear

(A)

MT-00275

MT-00276

ST

(A) Pinion shaft

(B) Bevel pinion

(C) Bevel gear

(D) Washer

( A )

( B )

( B )

( C )

( C )

( D )

( D )

MT-00277

MT-00278

ST

MT-00279

MT-97

MANUAL TRANSMISSION AND DIFFERENTIAL

FRONT DIFFERENTIAL ASSEMBLY

2) Remove oil seal.

D: ASSEMBLY

1. DIFFERENTIAL CASE ASSEMBLY

1) Install bevel gear and bevel pinion together with
washers, and  insert pinion shaft.

NOTE:
Face the chamfered side of washer toward gear.

2) Measure backlash between bevel gear and pin-
ion. If it is not  within specifications, install a suitable
washer to adjust it. <Ref. to MT-100, ADJUST-
MENT, Front Differential Assembly.>  

NOTE:
Be sure the pinion gear tooth contacts adjacent
gear teeth during  measurement.
ST1

498247001

MAGNET BASE

ST2

498247100

DIAL GAUGE

Standard backlash:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

3) Align pinion shaft and differential case at their
holes, and drive  straight pin into holes from the hy-
poid driven gear side, using  ST.

NOTE:
Lock straight pin after installing.
ST

899904100

REMOVER

(A) Bevel pinion

(B) Bevel gear

(C) Pinion shaft

MT-00363

( B )

( A )

( C )

MT-00284

(A) Pinion shaft

(B) Differential case

(C) Straight pin

MT-00285

ST1

ST2

MT-00286

( A )

( B )

( C )

MT-98

MANUAL TRANSMISSION AND DIFFERENTIAL

FRONT DIFFERENTIAL ASSEMBLY

4) Install roller bearing to differential case.

NOTE:
• Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
• Be careful because roller bearing outer races are
used as a set.
ST1

499277100

BUSHING 1-2 INSTALLER

ST2

398497701

ADAPTER

5) Install hypoid driven gear to differential case us-
ing twelve bolts.

Tightening torque:

T: 62 N·m (6.3 kgf-m, 45.6 ft-lb)

6) Position drive axle shaft in differential case and
hold it with outer snap ring (28). Using a thickness
gauge, measure clearance between the shaft and
case is within specifications.

NOTE:
It it is not within specifications, replace snap ring
with a suitable one.

Clearance:

0 — 0.25 mm (0 — 0.0098 in)

2. SIDE RETAINER

1) Install bearing outer race to side retainer.

NOTE:
Press-in while being careful not to scratch side re-
tainer and bearing outer race.
2) Install new oil seal.
ST

499797000

INSTALLER

(A) Hypoid driven gear

(B) Differential case

MT-00287

ST1

ST2

MT-00288

( A )

( B )

T

Snap ring (Outer-28)

Part No.

Thickness mm (in)

805028011

1.05 (0.0413)

805028012

1.20 (0.0472)

MT-00365

MT-00364

ST

MT-99

MANUAL TRANSMISSION AND DIFFERENTIAL

FRONT DIFFERENTIAL ASSEMBLY

3) Install new O-ring.

NOTE:
Do not stretch or damage O-ring.

E: INSPECTION

Repair or replace the differential gear in the follow-
ing cases:
• The hypoid drive gear and drive pinion shaft
tooth surface  are damaged, excessively worn, or
seized.
• The roller bearing on the drive pinion shaft has a
worn or  damaged roller path.
• There is damage, wear, or seizure of the differ-
ential bevel  pinion, differential bevel gear, washer,
pinion shaft, and straight  pin.
• The differential case has worn or damaged slid-
ing surfaces.

MT-00279

(A) Drive pinion shaft

(B) Hypoid driven gear

(C) Pinion shaft

(D) Straight pin

(E) Washer

(F) Differential bevel gear

(G) Differential bevel pinion

MT-00291

(A)

(B)

(C)

(E)

(E)

(F)

(F)

(G)

(G)

(D)