Subaru Legacy III (2000-2003 year). Manual - part 676

DI-58

DIFFERENTIALS

REAR DIFFERENTIAL FRONT OIL SEAL

6. Rear Differential Front Oil 

Seal

A: INSPECTION

Check front oil seal portion for oil leakage, if any
leak is found, replace the oil seal and inspect pro-
peller shaft.

B: REPLACEMENT

1) Disconnect ground cable from battery.
2) Move select lever or gear shift lever to “N”.
3) Release the parking brake.
4) Remove oil drain plug, and drain gear oil.

5) Install oil drain plug.

NOTE:
• Apply fluid packing to oil drain plug in T-type.
• VA-type uses a new aluminum gasket.

Fluid packing:

THREE BOND 1105 (Part No. 004403010) or 
equivalent

Tightening torque:

T-type;

49 N·m (5.0 kgf-m, 36.2 ft-lb)

VA-type;

34 N·m (3.5 kgf-m, 25.3 ft-lb)

6) Jack-up rear wheels and support the vehicle
body with sturdy racks.
7) Remove rear exhaust pipe and muffler.
8) Remove propeller shaft from body. <Ref. to DS-
14, REMOVAL, Propeller Shaft.>

9) Remove self-locking nut while holding compan-
ion flange with ST.
ST

498427200

FLANGE WRENCH

10) Remove protector nuts.

11) Extract companion flange using ST.
ST

399703602

PULLER ASSY

12) Remove oil seal using ST.
ST

398527700

PULLER ASSY

(A) Filler plug

(B) Drain plug

DI-00291

( A )

( B )

DI-00194

ST

DI-00271

DI-00196

ST

DI-00197

ST

DI-59

DIFFERENTIALS

REAR DIFFERENTIAL FRONT OIL SEAL

13) Fit a new oil seal using ST.
ST

498447120

OIL SEAL INSTALLER

14) Install companion flange.

NOTE:
Use a plastic hammer to install companion flange.
15) Tighten self-locking nut within the specified
torque range so that the turning resistance of com-
panion flange becomes the same as that before re-
placing oil seal.
ST

498427200

FLANGE WRENCH

NOTE:
Use a new self-locking nut.

Tightening torque:

181.4 N·m (18.50 kgf-m, 133.8 ft-lb)

16) Reassembling procedure hereafter is the re-
verse of the disassembling.

DI-00292

ST

DI-00194

ST

DI-60

DIFFERENTIALS

REAR DIFFERENTIAL FRONT MEMBER

7. Rear Differential Front Mem-

ber

A: REMOVAL

1) Disconnect ground cable from battery.
2) Jack-up the vehicle.
3) Using a transmission jack, support rear differen-
tial, and remove rear differential front member.

B: INSTALLATION

1) Install rear differential front member.

Tightening torque:

T1: 65 N·m (6.6 kgf-m, 48 ft-lb)
T2: 110 N·m (11.2 kgf-m, 81 ft-lb)

C: INSPECTION

1) Check rear differential front member for dam-
age, bend, or corrosion.
If damage, bend, or corrosion is excessive, replace
rear differential front member. 
2) Check bushings of rear differential front member
for cracking, hardening, or damage.
If cracking, hardening, or damage is excessive, re-
place rear differential front member.

(A) Rear differential front member

DI-00293

( A )

DI-00294

T2

T1

DI-61

DIFFERENTIALS

GENERAL DIAGNOSTIC TABLE

8. General Diagnostic Table

A: INSPECTION

Symptom or trouble

Possible cause

Remedy

1. Oil leakage

Worn, scratched, or incorrectly seated 
front or side oil seal. Scored, battered, or 
excessively worn sliding surface of com-
panion flange.

Repair or replace.

Clogged or damaged air breather.

Clean, repair or replace.

Loose bolts on side retainer, or incor-
rectly fitted O-ring.

Tighten bolts to specified torque. Replace 
O-ring.

Loose rear cover attaching bolts or dam-
aged gasket.

Tighten bolts to specified torque. Replace 
gasket and apply liquid packing.

Loose oil filler or drain plug.

Retighten and apply liquid packing.

Wear, damage or incorrectly fitting for 
side retainer and oil seal.

Repair or replace.

2. Seizure
NOTE:
Seized or damaged parts should be re-
placed, and also other parts should be
thoroughly checked for any defect and
should be repaired or replaced as re-
quired.

Insufficient backlash for hypoid gear.

Readjust or replace.

Excessive preload for side, rear, or front 
bearing.

Readjust or replace.

Insufficient or improper oil used.

Replace seized part and fill with specified 
oil to specified level.

3. Damage
NOTE:
Damaged parts should be replaced, and
also other parts should be thoroughly
checked for any defect and should be re-
paired or replaced as required.

Improper backlash for hypoid gear.

Replace.

Insufficient or excessive preload for side, 
rear, or front bearing.

Readjust or replace.

Excessive backlash for differential gear.

Replace gear or thrust washer.

Loose bolts and nuts such as crown gear 
bolt.

Retighten.

Damage due to overloading.

Replace.

4. Noises when starting or shifting 
gears
NOTE:
Noises may be caused by differential as-
sembly, universal joint, wheel bearing,
etc. Find out what is actually making noise
before disassembly.

Excessive backlash for hypoid gear.

Readjust.

Excessive backlash for differential gear.

Replace gear or thrust washer.

Insufficient preload for front or rear bear-
ing.

Readjust.

Loose drive pinion nut.

Tighten to specified torque.

Loose bolts and nuts such as side bear-
ing retainer attaching bolt.

Tighten to specified torque.

5. Noises when cornering

Damaged differential gear.

Replace.

Excessive wear or damage of thrust 
washer.

Replace.

Broken pinion mate shaft.

Replace.

Seized or damaged side bearing.

Replace.

6. Gear noises
NOTE:
Since noises from engine, muffler, trans-
mission, propeller shaft, wheel bearings,
tires, and body are sometimes mistaken
for noises from differential assembly, be
careful in checking them. Inspection
methods to locate noises include coast-
ing, accelerating, cruising, and jacking-up
all four wheels. Perform these inspections
according to condition of trouble. When
listening to noises, shift gears into four
wheel drive and fourth speed position, try-
ing to pick up only differential noise.

Improper tooth contact of hypoid gear.

Readjust or replace hypoid gear set.

 Improper backlash for hypoid gear.

Readjust.

Scored or chipped teeth of hypoid gear.

Replace hypoid gear set.

Seized hypoid gear.

Replace hypoid gear set.

Improper preload for front or rear bear-
ings.

Readjust.

Seized, scored, or chipped front or rear 
bearing.

Replace.

Seized, scored, or chipped side bearing.

Replace.

Vibrating differential carrier.

Replace.