Content .. 667 668 669 670 ..

Subaru Legacy III (2000-2003 year). Manual - part 669

DI-30

DIFFERENTIALS

REAR DIFFERENTIAL FOR T-TYPE

17) Remove rear bearing cone from drive pinion by
supporting cone with ST.

NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST

398517700

REPLACER

18) Remove front oil seal from differential carrier
using ST.
ST

398527700

PULLER ASSY

19) Remove pilot bearing together with front bear-
ing cone using ST.
ST

398467700

DRIFT

20) When replacing bearings, tap front bearing cup
and rear bearing cup in this order out of case by us-
ing a brass bar.

D: ASSEMBLY

NOTE:
• Assemble in the reverse order of disassembling.
• Check and adjust each part during assembly.
• Keep the shims and washers in order, so that
they are not misinstalled.
• 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 right and left hand
races of the bearings.
• Replace the oil seal with new one at every disas-
sembly. Apply chassis grease between the lips
when installing the oil seal.

• Use new O-rings and gaskets.

(A) Pinion bearing

(B) Front bearing

DI-00074

DI-00075

DI-00076

( A )

( B )

( C )

(A) 2 cutouts along diagonal lines

(B) Tap alternately with brass bar.

DI-00077

( A )

( B )

DI-00078

DI-31

DIFFERENTIALS

REAR DIFFERENTIAL FOR T-TYPE

1) Adjusting preload for front and rear bearings
Adjust the bearing preload with spacer 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) Press rear bearing race (rear) into differen-
tial carrier with ST1 and ST2.

ST1

398477701

HANDLE

ST2

398477703

DRIFT 2

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

ST1

398477701

HANDLE

ST2

398477702

DRIFT

(3) Insert ST1 into carrier with pinion height ad-
justing washer and new rear bearing cone fitted
onto it.

NOTE:
Before assembly inspection, when tooth contact is
normal, confirm that washer is not deformed and
re-use the used washer.

(4) Then install preload adjusting spacer and
washer, front bearing cone, ST2, companion
flange, and washer and drive pinion nut.

ST1

398507702

DUMMY SHAFT

ST2

398507703

DUMMY COLLAR

(5) Turn ST1 with hand to make it seated, and
tighten drive pinion nut while measuring the pre-
load with spring balance. Select preload adjust-
ing washer and spacer so that the specified
preload is obtained when nut is tightened to the
specified torque.

NOTE:
• Use a new lock nut.
• Be careful not to give excessive preload.
• When tightening the drive pinion nut, lock ST1
with ST2 as shown in the figure.
ST1

398507704

BLOCK

ST2

398507702

DUMMY SHAFT

Tightening torque:

181 N·m (18.5 kgf-m, 134 ft-lb)

(A) Pinion height adjusting shim

(B) Preload adjusting spacer

DI-00079

ST1

ST2

DI-00080

( A )

( B )

( C )

ST2

ST1

Front and rear bearing preload

For new bearing:
19.6 — 28.4 N (2.0 — 2.9 kgf, 4.4 — 6.4 lb)
at companion flange bolt hole

For used bearing:
8.34 — 16.67 N (0.85 — 1.7 kgf, 1.87 — 3.75 lb)
at companion flange bolt hole

DI-00081

ST2

ST1

DI-00117

DI-32

DIFFERENTIALS

REAR DIFFERENTIAL FOR T-TYPE

2) Adjusting drive pinion height
Adjust drive pinion height with shim installed be-
tween rear bearing cone and the back of pinion
gear.

(1) Make sure that pinion bearing preload ad-
justment on previous item is complete for ST1,
ST2 and ST3.

Adjusting preload for front and rear bearings

NOTE:
At this time, install a pinion height adjusting shim
which is temporarily selected or the same as that
used before. Measure and record the thickness.
ST1

398507702

DUMMY SHAFT

ST2

398507701

DIFFERENTIAL CARRIER
GAUGE

ST3

398507703

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

398507702

DUMMY SHAFT

ST2

398507701

DIFFERENTIAL CARRIER
GAUGE

Preload adjusting
washer

Part No.

Thickness mm

(in)

383705200

2.59 (0.1020)

383715200

2.57 (0.1012)

383725200

2.55 (0.1004)

383735200

2.53 (0.0996)

383745200

2.51 (0.0988)

383755200

2.49 (0.0980)

383765200

2.47 (0.0972)

383775200

2.45 (0.0965)

383785200

2.43 (0.0957)

383795200

2.41 (0.0949)

383805200

2.39 (0.0941)

383815200

2.37 (0.0933)

383825200

2.35 (0.0925)

383835200

2.33 (0.0917)

383845200

2.31 (0.0909)

Preload adjusting
spacer

Part No.

Length mm (in)

383695201

56.2 (2.213)

383695202

56.4 (2.220)

383695203

56.6 (2.228)

383695204

56.8 (2.236)

383695205

57.0 (2.244)

383695206

57.2 (2.252)

Front and rear bearing preload

For new bearing:
19.6 — 28.4 N (2.0 — 2.9 kgf, 4.4 — 6.4 lb)
at companion flange bolt hole

For used bearing:
8.34 — 16.67 N (0.85 — 1.7 kgf, 1.87 — 3.75 lb)
at companion flange bolt hole

(A) Pinion height adjusting shim

DI-00083

( A )

ST3

ST1

ST2

DI-00084

ST1

ST2

DI-33

DIFFERENTIALS

REAR DIFFERENTIAL FOR T-TYPE

(3) Obtain the thickness of pinion height adjust-
ing shim to be inserted from the following formu-
la, and replace the temporarily installed shim
with this one.

T = To + N

−

(H x 0.01)

−

0.20 mm (0.0079 in)

NOTE:
Use copies of this page.

(Example of calculation)

To = 2.20 + 1.20 = 3.40 mm
N = 0.23 mm
H = + 1,
T = 3.40 + 0.23

−

0.01

−

0.20 = 3.42

Result: Thickness = 3.42 mm

Therefore use the shim 383605200.

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

398177700

INSTALLER

4) Insert drive pinion into differential carrier, install
the previously selected bearing preload adjusting
spacer and washer.

5) Press-fit front bearing cone into case with ST1,
ST2 and ST3.
ST1

398507703

DUMMY COLLAR

ST2

399780104

WEIGHT

ST3

899580100

INSTALLER

Thickness of pinion height adjusting
shim mm (in)

Thickness of shim temporarily inserted
mm (in)

Reading of thickness gauge mm (in)

Figure marked on drive pinion head

Memo:

Pinion height adjusting shim

Part No.

Thickness mm (in)

383495200

3.09 (0.1217)

383505200

3.12 (0.1228)

383515200

3.15 (0.1240)

383525200

3.18 (0.1252)

383535200

3.21 (0.1264)

383545200

3.24 (0.1276)

383555200

3.27 (0.1287)

383565200

3.30 (0.1299)

383575200

3.33 (0.1311)

383585200

3.36 (0.1323)

383595200

3.39 (0.1335)

383605200

3.42 (0.1346)

383615200

3.45 (0.1358)

383625200

3.48 (0.1370)

383635200

3.51 (0.1382)

383645200

3.54 (0.1394)

383655200

3.57 (0.1406)

383665200

3.60 (0.1417)

383675200

3.63 (0.1429)

383685200

3.66 (0.1441)

(A) Drive pinion

(B) Bearing adjusting spacer

(D) Differential carrier

DI-00085

DI-00086

( D )

( C )

( B )

( A )

DI-00087

ST2

ST1

ST3

Content .. 667 668 669 670 ..