Subaru Legacy III (2000-2003 year). Manual - part 673

DI-46

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-TYPE

12) Drive out pinion shaft lock pin from crown gear
side.

NOTE:
The lock pin is staked at the pin hole end on the dif-
ferential case; do not drive it out forcibly before
unstaking it.
ST

899904100

STRAIGHT PIN REMOVER

13) Draw out pinion mate shaft and remove pinion
mate gears, side gears and thrust washers.

NOTE:
The gears as well as thrust washers should be
marked or kept separated left and right, and front
and rear.

14) Hold companion flange with ST and remove
self-locking nut.
ST

498427200

FLANGE WRENCH

15) Extract the companion flange with a puller.

16) Press the end of drive pinion shaft and extract it
together with rear bearing cone, preload adjusting
spacer and washer.

NOTE:
Hold the drive pinion so as not to drop it.
ST

398467700

DRIFT

(A) Side gear

(B) Pinion mate gear

(D) Differential case

(E) Pinion mate shaft

DI-00237

DI-00238

( A )

( B )

( C )

( D )

( E )

(A) Companion

(B) Puller

DI-00141

DI-00142

( A )

( B )

DI-00073

DI-47

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-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

498515500

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) Differential carrier

(B) Front oil seal

(A) Pilot bearing

(B) Front bearing

DI-00074

DI-00145

( A )

( B )

DI-00076

( A )

( B )

( C )

(A) 2 cutouts along diagonal lines

(B) Tap alternately with brass bar.

DI-00077

( A )

( B )

DI-00078

DI-48

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-TYPE

1) Adjust 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

398477702

DRIFT

(2) Press front bearing race (front) into differen-
tial carrier with ST1 and ST2.

ST1

398477701

HANDLE

ST2

498447110

DRIFT

(3) Insert new front bearing cone.
(4) Insert ST1 into case with pinion height ad-
justing shim 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.

(5) Then install preload adjusting spacer and
washer, front bearing cone, ST2, companion
flange, and washer and self-locking nut.

ST1

498447150

DUMMY SHAFT

ST2

32285AA000 DUMMY COLLAR

(6) 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 self-locking nut.
• Be careful not to give excessive preload.
• When tightening the drive pinion nut, lock ST2
with ST1 as shown in the figure.
ST1

398507704

BLOCK

ST2

498447150

DUMMY SHAFT

Tightening torque:

188 N·m (19.2 kgf-m, 139 ft-lb)

(A) Pinion height adjusting shim

(B) Preload adjusting spacer

DI-00149

ST1

ST2

DI-00150

( A )

( B )

( C )

ST2

ST1

Front and rear bearing preload

For new bearing:
12.7 — 32.4 N (1.3 — 3.3 kgf, 2.9 — 7.3 lb)
at companion flange bolt hole

DI-00081

ST2

ST1

DI-00152

DI-49

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-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) Install ST1, ST2 and ST3, as shown in the
figure, and apply the specified preload on the
bearings

Adjusting preload for front and rear bearings

NOTE:
At this time, install an original pinion height adjust-
ing shim.
ST1

498447150

DUMMY SHAFT

ST2

32285AA000 DUMMY COLLAR

ST3

498505501

DIFFERENTIAL CARRIER
GAUGE

(2) Measure the clearance N between the end
of ST3 and the end surface of ST1 by using a
thickness gauge.

NOTE:
Make sure there is no clearance between the case
and ST3.
ST1

498447150

DUMMY SHAFT

ST2

498505501

DIFFERENTIAL CARRIER
GAUGE

Preload adjusting
washer

Part No.

Thickness mm (in)

38336AA000

1.500 (0.0591)

38336AA120

1.513 (0.0596)

38336AA010

1.525 (0.0600)

38336AA130

1.538 (0.0606)

38336AA020

1.550 (0.0610)

38336AA140

1.563 (0.0615)

38336AA030

1.575 (0.0620)

38336AA150

1.588 (0.0625)

38336AA040

1.600 (0.0630)

38336AA160

1.613 (0.0635)

38336AA050

1.625 (0.0640)

38336AA170

1.638 (0.0645)

38336AA060

1.650 (0.0650)

38336AA180

1.663 (0.0655)

38336AA070

1.675 (0.0659)

38336AA190

1.688 (0.0665)

38336AA080

1.700 (0.0669)

38336AA200

1.713 (0.0674)

38336AA090

1.725 (0.0679)

38336AA210

1.738 (0.0684)

38336AA100

1.750 (0.0689)

38336AA220

1.763 (0.0694)

38336AA110

1.775 (0.0699)

Preload adjusting
spacer

Part No.

Length mm (in)

32288AA040

52.3 (2.059)

32288AA050

52.5 (2.067)

31454AA100

52.6 (2.071)

32288AA060

52.7 (2.075)

31454AA110

52.8 (2.079)

32288AA070

52.9 (2.083)

31454AA120

53.0 (2.087)

32288AA080

53.1 (2.091)

32288AA090

53.3 (2.098)

Front and rear bearing preload

For new bearing:
12.7 — 32.4 N (1.3 — 3.3 kgf, 2.9 — 7.3 lb)
at companion flange bolt hole

(A) Pinion height adjusting shim

DI-00082

( A )

ST2

ST1

ST3

DI-00084

ST1

ST2

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