Subaru Legacy III (2000-2003 year). Manual - part 675

DI-54

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-TYPE

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

Backlash:

0.10 — 0.15 mm (0.0039 — 0.0059 in)

17) 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-00172

AT-00207

(A)

(B)

AT-00208

AT-00212

AT-00209

DI-55

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-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.

NOTE:
Be sure to wipe off red lead completely after adjust-
ment is completed.
18) If proper tooth contact is not obtained, once
again adjust the drive pinion height and the differ-
ential side bearing preload (already mentioned)
and the hypoid gear backlash.
19) Install new gasket and rear cover, and tighten
bolts to specified torque.

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

AT-00213

AT-00210

AT-00213

(A) Rear cover

AT-00211

AT-00212

( A )

DI-00189

DI-56

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-TYPE

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.

Side gear backlash:

0.05 — 0.15 mm (0.0020 — 0.0059 in)

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

2. CROWN GEAR BACKLASH

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

Crown gear backlash:

0.10 — 0.15 mm (0.0039 — 0.0059 in)

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

DI-00286

DI-00099

DI-57

DIFFERENTIALS

REAR DIFFERENTIAL FOR VA-TYPE

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
drive pinion.
<Ref. to DI-47, ASSEMBLY, Rear Differential for
VA-type.>

F: ADJUSTMENT

1. SIDE GEAR BACKLASH

Adjust side gear backlash.
<Ref. to DI-47, ASSEMBLY, Rear Differential for
VA-type.>

2. CROWN GEAR BACKLASH

Adjust crown gear backlash.
<Ref. to DI-47, ASSEMBLY, Rear Differential for
VA-type.>

3. TOOTH CONTACT BETWEEN CROWN 
GEAR AND DRIVE PINION

Adjust the tooth contact between crown gear and
drive pinion gear. 
<Ref. to DI-47, ASSEMBLY, Rear Differential for
VA-type.>

DI-00101