Subaru Legacy III (2000-2003 year). Manual - part 674

DI-50

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-TYPE

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

NOTE:
Use 1 to 3 shims as required for adjustment.

T = To + N 

−

 0.05 (mm)

where

T = Thickness of pinion height adjusting shim

(mm)

To = Thickness of shim originally installed

(mm)

N = Reading of thickness gauge (mm)
H = Figure marked on drive pinion head

(Example of calculation)

To = 0.15 mm
N = 0.1 mm
T = 0.15 + 0.1 

−

 0.05 = 0.2 mm

Result: Thickness = 0.2 mm

Therefore use the 32295AA220.

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

498175500

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 carrier with ST1,
ST2 and ST3.
ST1

32285AA000 DUMMY COLLAR

ST2

399780104

WEIGHT

ST3

899580100

INSTALLER

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

399780104

WEIGHT

ST2

899580100

INSTALLER

Pinion height adjusting shim

Part No.

Thickness mm (in)

32295AA200

0.150 (0.0059)

32295AA210

0.175 (0.0069)

32295AA220

0.200 (0.0079)

32295AA230

0.225 (0.0089)

32295AA240

0.250 (0.0098)

32295AA250

0.275 (0.0108)

DI-00085

ST

(A) Drive pinion

(B) Bearing preload adjusting spacer

(C) Bearing preload adjusting washer

(D) Differential carrier

DI-00086

( D )

( C )

( B )

( A )

DI-00087

ST2

ST1

ST3

DI-00088

ST2

ST1

DI-51

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-TYPE

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 self-locking nut. Then tighten it with ST.
ST

398427200

FLANGE WRENCH

Tightening torque:

188 N·m (19.2 kgf-m, 139 ft-lb)

10) Assembling differential case
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.

(1) Measure the side gear backlash.

Side gear back clearance:

0.05 — 0.15 mm (0.0020 — 0.0059 in)

(2) Adjust the side gear backlash as specified
by selecting side gear thrust washer.

(3) Check the condition of rotation after apply-
ing oil to the gear tooth surfaces and thrust sur-
faces.

ST

DI-00089

DI-00090

ST1

ST2

DI-00161

ST

Side gear thrust washer

Part No.

Thickness mm (in)

803135011

0.925 — 0.950 (0.0364 — 0.0374)

803135012

0.950 — 0.975 (0.0374 — 0.0384)

803135013

0.975 — 1.000 (0.0384 — 0.0394)

803135014

1.000 — 1.025 (0.0394 — 0.0404)

803135015

1.025 — 1.050 (0.0404 — 0.0413)

DI-00239

DI-00240

DI-52

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-TYPE

(4) After driving in pinion shaft lock pin, stake
the both sides of the hole to prevent pin from fall-
ing off.
(5) 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:

62 N·m (6.3 kgf-m, 45.6 ft-lb)

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

498485400

DRIFT

12) Assemble holders.

(1) Install oil seal into right and left holders.

ST

498447100

AXLE SHAFT OIL SEAL IN-
STALLER

(2) Install bearing race into right and left hold-
ers.

ST

398477702

BEARING OUTER RACE 
DRIFT

(3) Install the differential case assembly into dif-
ferential carrier in the reverse order of disas-
sembly.

(4) Lightly screw-in side holders of RH an LH
into differential carrier and install.

13) Perform adjustment of backlash of pinion
crown gear set and adjustment of preload of differ-
ential side bearing.

(1) Turn drive pinion with ST for better fitting of
differential side bearing.

ST

498427200

FLANGE WRENCH

DI-00068

ST

DI-00095

DI-00166

ST

ST

DI-00167

DI-00134

ST

DI-00169

DI-53

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-TYPE

(2) Screw in side (left-side) holder until light
contact is made with ST.

ST

399780111

WRENCH

(3) Back off side (left-side) holder approximate-
ly 1 1/2 teeth of holder, and tighten left-side
holder by approximately 2 teeth (approximately
1 1/2 + 1/2 teeth).
[Back off amount of side (left-side) holder + 1/2
tooth.]
This + 1/2 tooth gives preload.
(4) Temporarily tighten lock plate.

NOTE:
Turn over lock plate to displace holder 1/2 tooth.

(5) 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.

NOTE:
If measured backlash is not within specified range,
repeat procedures for pinion crown gear set back-
lash adjustment and differential side bearing pre-
load adjustment.

Backlash:

0.10 — 0.15 mm (0.0039 — 0.0059 in)

14) Draw a matching mark on both differential car-
rier and holder. Remove holder one side at a time.
Replace in the original position after inserting an O-
ring and applying grease to threaded portion.

15) Tighten bolt of lock plate to specified torque.

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

DI-00133

ST

DI-00132

(A) Matching mark

(B) Holder

DI-00172

DI-00173

( A )

( B )

DI-00132