Subaru Legacy III (2000-2003 year). Manual - part 671

DI-38

DIFFERENTIALS

REAR DIFFERENTIAL FOR T-TYPE

Corrective action: Reduce thickness of drive pinion
height adjusting shim in order to move drive pinion
away from crown gear.

• Toe contact (Inside end contact)
Checking item: Contact area is small.
Contact pattern

Corrective action: Reduce thickness of drive pinion
height adjusting shim in order to move drive pinion
away from crown gear.

• Heel contact (Outside end contact)
Checking item: Contact area is small.
Contact pattern

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

19) If proper tooth contact is not obtained, once
again adjust the drive pinion height changing RH
and LH side bearing retainer shims and the hypoid
gear backlash.
20) Remove LH/RH side bearing retainers.
21) Install O-ring and side retainer shim on side
bearing retainer on LH/RH.
22) Align the arrow mark on differential carrier with
the mark on side retainer during installation.

AT-00213

AT-00210

AT-00213

(A) Arrow mark

AT-00211

AT-00212

DI-00097

( A )

DI-39

DIFFERENTIALS

REAR DIFFERENTIAL FOR T-TYPE

23) Tighten the side bearing retainer bolts.

Lock Tite:

THREE BOND 1105 (Part No.: 004403010) 
or equivalent

Tightening torque:

10.5 N·m (1.07 kgf-m, 7.7 ft-lb)

24) Install a new gasket and rear cover, and tighten
bolts to specified torque.

Tightening torque:

29 N·m (3.0 kgf-m, 21.7 ft-lb)

E: INSPECTION

Wash all the disassembled parts clean, and exam-
ine them for wear, damage, or other defects. Re-
pair or replace defective parts as necessary.
1) Crown gear and drive pinion
• If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact at as-
sembly. Replace the gear if excessively worn or in-
capable 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) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, abnormal 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. (Without LSD)

Side gear backlash:

0.1 — 0.2 mm (0.004 — 0.008 in)

If side gear backlash is not within the specification,
adjust clearance as specified by selecting side gear
thrust washer.

DI-00098

DI-00113

DI-00286

DI-40

DIFFERENTIALS

REAR DIFFERENTIAL FOR T-TYPE

2. CROWN GEAR BACKLASH

Using a dial gauge, check the backlash of the
crown gear.

Crown gear backlash:

0.1 — 0.2 mm (0.004 — 0.008 in)

If crown gear backlash is not within the specifica-
tion, adjust the side bearing preload or repair if nec-
essary.

3. CROWN GEAR RUNOUT

Using a dial gauge, check the crown gear runout.

Crown gear runout:

Less than 0.05 mm (0.0020 in)

If the crown gear runout exceeds 0.05 mm (0.0020
in), replace the crown gear. 

4. TOOTH CONTACT BETWEEN CROWN 
GEAR AND DRIVE PINION

Inspect tooth contact between crown gear and driv-
en pinion. <Ref. to DI-30, ASSEMBLY, Rear Differ-
ential for T-type.>

5. TOTAL PRELOAD

Using a gauge, check the turning resistance in-
crease.

Turning resistance increase:

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

If the increase of the resistance is not within the
specification, adjust the side bearing retainer
shims.

F: ADJUSTMENT

1. SIDE GEAR BACKLASH

Adjust side gear backlash.
<Ref. to DI-30, ASSEMBLY, Rear Differential for T-
type.>

2. CROWN GEAR BACKLASH

Adjust crown gear backlash.
<Ref. to DI-30, ASSEMBLY, Rear Differential for T-
type.>

3. TOOTH CONTACT BETWEEN CROWN 
GEAR AND DRIVE PINION

Adjust the tooth contact between crown gear and
drive pinion gear. 
<Ref. to DI-30, ASSEMBLY, Rear Differential for T-
type.>

4. TOTAL PRELOAD

Adjust side bearing shim.
<Ref. to DI-30, ASSEMBLY, Rear Differential for T-
type.>

DI-00099

DI-00101

DI-00117

DI-41

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-TYPE

5. Rear Differential for VA-type

A: REMOVAL

1) Disconnect ground cable from battery.
2) Move select lever or gear shift lever to “N”.
3) Loosen wheel nuts.
4) Release the parking brake.
5) Jack-up vehicle and support it with sturdy racks.
6) Remove wheels.
7) Remove rear exhaust pipe and muffler.
8) Remove heat shield cover.

9) Remove propeller shaft.
<Ref. to DS-14, REMOVAL, Propeller Shaft.>
10) Prepare a transmission jack and a band.

11) Loosen self-locking nuts connecting rear differ-
ential to rear crossmember.

12) Remove DOJ of rear drive shaft from rear dif-
ferential.

13) Remove protector nuts.

14) Remove nuts which secure rear differential
front member.

15) Support rear differential with transmission jack.

16) Remove rear differential front member.
17) Fix rear differential at band.

DI-00267

DI-00268

DI-00269

(A) Tire lever

(B) Bolt

DI-00287

( A )

( B )

DI-00271

DI-00272

DI-00273