Subaru Legacy III (2000-2003 year). Manual - part 670

DI-34

DIFFERENTIALS

REAR DIFFERENTIAL FOR T-TYPE

6) Insert spacer, then press-fit pilot bearing with
ST1 and ST2.
ST1

399780104

WEIGHT

ST2

899580100

INSTALLER

7) Fit a new oil seal with ST.

NOTE:
• Press-fit until end of oil seal is 1 mm (0.04 in) in-
ward from end of carrier.
• Apply grease between the oil seal lips.
ST

498447120

OIL SEAL INSTALLER

8) Press-fit companion flange with ST1 and ST2.

NOTE:
Be careful not to damage bearing.
ST1

899874100

INSTALLER

ST2

399780104

WEIGHT

9) Install new self-locking nut, fix companion flange
with ST and then tighten.
ST

498427200

FLANGE WRENCH

Tightening torque:

181 N·m (18.5 kgf-m, 134 ft-lb)

10) Assembling differential case (Without LSD)
Install side gears and pinion mate gears, with their
thrust washers and pinion mate shaft, into differen-
tial case.

NOTE:
• Apply gear oil on both sides of the washer and on
the side gear shaft before installing.
• Insert the pinion mate shaft into the differential
case by aligning the lock pin holes.

DI-00088

ST2

ST1

ST

DI-00089

DI-00090

ST1

ST2

DI-00091

ST

DI-00239

DI-35

DIFFERENTIALS

REAR DIFFERENTIAL FOR T-TYPE

(1) Measure the side gear backlash.

Side gear back clearance:

0.10 — 0.20 mm (0.0039 — 0.0079 in)

(2) Adjust the backlash as specified by select-
ing side gear thrust washer.

(3) Check the condition of rotation after apply-
ing oil to the gear tooth surfaces and thrust sur-
faces.
(4) After inserting pinion shaft lock pin into dif-
ferential case, stake the both sides of the hole to
prevent pin from falling off.

11) Install crown gear on differential case.

NOTE:
• Before installing bolts, apply Lock Tite to bolt
threads.

Lock Tite:

THREE BOND 1324 (Part No.: 004403042) 
or equivalent

• Tighten diagonally while tapping the bolt heads.

Tightening torque:

103 N·m (10.5 kgf-m, 76 ft-lb)

12) Press side bearing cone onto differential case
with ST.
ST

398487700

DRIFT

NOTE:
When replacing bearing cone, replace it with bear-
ing cap as a set.

13) Install bearing cup to side bearing retainer.

NOTE:
• Press in while be careful not to scratch bearing
cup and side bearing retainer.
• When replacing bearing cup, replace it with bear-
ing cone as a set.
14) Using ST, press in new oil seal to side bearing
retainer.
ST

398437700

DRIFT

NOTE:
Apply thin oil gear oil on the mating surface of side
bearing retainer and oil seal.
15) Adjusting side bearing retainer shims

(1) The driven gear backlash and side bearing
preload can be determined by the side bearing
retainer shim thickness.
(2) Install the differential case assembly into dif-
ferential carrier in the reverse order of disas-
sembly.

Side gear thrust washer

Part No.

Thickness mm (in)

383445201

0.75 — 0.80 (0.0295 — 0.0315)

383445202

0.80 — 0.85 (0.0315 — 0.0335)

383445203

0.85 — 0.90 (0.0335 — 0.0354)

383445204

0.90 — 0.95 (0.0354 — 0.0374)

383445205

0.95 — 1.00 (0.0374 — 0.0394)

DI-00240

DI-00068

ST

DI-00095

DI-00065

DI-36

DIFFERENTIALS

REAR DIFFERENTIAL FOR T-TYPE

(3) Install side retainer shims to the left and
right retainers from which they were removed.

NOTE:
• Replace broken or cracked O-ring with new one.
• Replace broken or corroded side retainer shim
with new one of same thickness.

(4) Align arrow marked on differential carrier
with that marked on side retainer during installa-
tion.

NOTE:
Be careful that side bearing outer race is not dam-
aged by bearing roller.

(5) Tighten side bearing retainer bolts.

Tightening torque:

10.3 N·m (1.05 kgf-m, 7.6 ft-lb)

(6) Measure the crown gear-to-drive pinion
backlash. Set magnet base on differential carri-
er. Align contact point of dial gauge with tooth
face of crown gear, and move crown gear while
holding drive pinion still. Read value indicated
on dial gauge.
When backlash is out of standard range, adjust
side retainer shim with the following procedure.
When backlash is more than 0.20 mm (0.0079
in):
Reduce shim thickness on crown gear back, in-
crease shim thickness on crown gear side.
When backlash is less than 0.10 mm (0.0039
in):
Increase shim thickness on crown gear back, re-
duce shim thickness on crown gear side.

Backlash:

0.10 — 0.20 mm (0.0039 — 0.0079 in)

(7) At the same time, measure the turning resis-
tance of drive pinion. Compared with the resis-
tance when differential case is not installed,
when turning resistance increase is out of stan-
dard value, adjust by both increasing and de-
creasing with the same amount of side bearing
retainer shim thickness.

Turning resistance increase:

2.9 — 10.8 N (0.3 — 1.1 kgf, 0.7 — 2.4 lb)

16) Re-check crown gear-to-pinion backlash.

Backlash:

0.10 — 0.20 mm (0.0039 — 0.0079 in)

Side bearing retainer shim

Part No.

Thickness mm (in)

383475201

0.20 (0.0079)

383475202

0.25 (0.0098)

383475203

0.30 (0.0118)

383475204

0.40 (0.0157)

383475205

0.50 (0.0197)

(A) Arrow mark

DI-00097

( A )

DI-00098

DI-00099

DI-00099

DI-37

DIFFERENTIALS

REAR DIFFERENTIAL FOR T-TYPE

17) Check the crown gear runout on its back sur-
face, and make sure pinion and crown gear rotate
smoothly.

Limit of runout:

Less than 0.05 mm (0.0020 in)

18) Checking and adjusting tooth contact of crown
gear

(1) Apply an even coat of red lead on both sides
of three or four teeth on the crown gear. Check
the contact pattern after rotating crown gear
several revolutions back and forth until a definite
contact pattern appears on the crown gear.
(2) When the contact pattern is incorrect, read-
just according to the instructions given in
“TOOTH CONTACT PATTERN”.

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 to toe side under no-load
rotation. (When loaded, contact pattern moves
toward heel)

• Face contact
Checking item: Backlash is too large.
Contact pattern

Corrective action: Increase thickness of drive pin-
ion height adjusting shim in order to bring drive pin-
ion close to crown gear.

• Flank contact
Checking item: Backlash is too small.
Contact pattern

(A) Toe side

(B) Heel side

DI-00101

AT-00207

(A)

(B)

AT-00208

AT-00212

AT-00209