Subaru Outback manuals

Subaru Outback: Rear Differential (T-type)

A: REMOVAL

1) Shift the select lever or gear shift lever to neutral.

2) Release the parking brake.

3) Disconnect the ground cable from battery.

4) Loosen the wheel nuts.

5) Lift up the vehicle.

6) Remove the rear wheels.

7) Drain differential gear oil. <Ref. to DI-23, REPLACEMENT, Differential Gear Oil.>

8) Remove the rear exhaust pipe.

9) Remove the heat shield cover.

Subaru Outback. Differentials

10) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.>

11) Loosen the self-lock nuts which hold the rear differential to rear crossmember.

Subaru Outback. Differentials

12) Remove the DOJ of rear drive shaft from rear differential using ST or tire lever.

NOTE:

T-type

ST 28099PA100 DRIVE SHAFT REMOVER

Subaru Outback. Differentials

  1. Bolt

VA-type

Subaru Outback. Differentials

  1. Tire lever
  2. Bolt

13) Set the rear differential to transmission jack.

Subaru Outback. Differentials

14) Remove the mass damper. (CVT model)

Subaru Outback. Differentials

15) Remove the rear differential front member.

Subaru Outback. Differentials

16) Remove the self-locking nuts which hold the rear differential to the crossmember.

Subaru Outback. Differentials

17) Pull out the rear differential stud bolt from rear crossmember bushing.

NOTE: When removing the stud bolt from the rear crossmember bushing, carefully adjust the angle and location of transmission jack and jack stand, if necessary.

Subaru Outback. Differentials

18) Lower the transmission jack.

19) Pull out the rear drive shaft from the rear differential.

NOTE:

ST 28099PA100 DRIVE SHAFT REMOVER

Subaru Outback. Differentials

20) Lower the transmission jack.

21) Secure the rear drive shaft to rear lateral link using wire.

Subaru Outback. Differentials

22) Remove the rear differential member plate from rear differential.

Subaru Outback. Differentials

  1. Rear differential member plate (CVT model)
  2. Rear differential member plate

B: INSTALLATION

1) Attach the rear differential member plate to the rear differential.

Subaru Outback. Differentials

  1. Rear differential member plate (CVT model)
  2. Rear differential member plate

2) Set the rear differential to transmission jack.

3) Set the ST to the rear differential.

ST 28099PA090 OIL SEAL PROTECTOR

Subaru Outback. Differentials

4) Insert the rear drive shaft until the spline portion of the rear drive shaft exceeds the side oil seal.

Subaru Outback. Differentials

5) Remove ST from rear differential.

6) Push the rear differential from side to side to insert the DOJ into rear differential completely.

Subaru Outback. Differentials

7) Adjust the transmission jack, if necessary, and insert the rear differential stud bolt into rear crossmember bushing properly.

Subaru Outback. Differentials

8) After inserting the rear differential stud bolt into the rear crossmember bushing, lift up the transmission jack and align the rear differential to its attachment position.

Subaru Outback. Differentials

9) Tighten a new self-locking nut temporarily to rear crossmember.

Subaru Outback. Differentials

10) Install the rear differential front member with a new self-locking nut.

Tightening torque:
T1: 50 N*m (5.1 kgf-m, 36.9 ft-lb)
T2: 110 N*m (11.2 kgf-m, 81.1 ft-lb)

Subaru Outback. Differentials

11) Install the mass damper with a new self-locking nut. (CVT model)

Tightening torque: 50 N*m (5.1 kgf-m, 36.9 ft-lb)

Subaru Outback. Differentials

12) Remove the transmission jack.

13) Tighten the self-locking nut.

NOTE: For models other than OUTBACK model, tighten the self-locking nut using the ST.

ST 41399YC000 SOCKET WRENCH (17)

Tightening torque: 70 N*m (7.1 kgf-m, 51.6 ft-lb)

Subaru Outback. Differentials

14) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.>

15) Install the heat shield cover.

Tightening torque: 18 N*m (1.8 kgf-m, 13.3 ft-lb)

Subaru Outback. Differentials

16) Install the rear exhaust pipe.

17) Fill differential gear oil. <Ref. to DI-23, REPLACEMENT, Differential Gear Oil.>

18) Installing procedure hereafter is in the reverse order of removal.

19) Perform "Rear differential inspection mode " using the Subaru Select Monitor. (CVT model) <Ref. to DI-84, Rear Differential Inspection Mode.>

CAUTION: Be sure to perform rear differential inspection mode when the following work has been performed.

C: DISASSEMBLY

To detect the real cause of trouble, inspect the following items before disassembling.

1) Set the ST on vise and install the differential assembly to ST.

ST 398217700 ATTACHMENT SET

Subaru Outback. Differentials

2) Remove the drain plug and filler plug.

3) Remove the air breather cap.

NOTE:

Subaru Outback. Differentials

  1. Air breather cap
  2. Rear cover

4) Remove the bolts, and then remove the rear cover.

5) Remove the side retainer attachment bolts, set the ST to differential case, and extract the side retainers RH and LH with a puller.

NOTE:

ST 398457700 ATTACHMENT

Subaru Outback. Differentials

6) Remove the oil seal from the side retainer.

7) Pull out the differential case assembly from the differential carrier.

NOTE: Be careful not to hit the teeth of hypoid driven gear against the differential carrier.

Subaru Outback. Differentials

8) When replacing the side bearing, remove the bearing race from the side retainer using ST.

ST 398527700 PULLER ASSY

Subaru Outback. Differentials

9) Using the ST, remove the bearing cone.

NOTE:

ST 18759AA000 PULLER ASSY

Subaru Outback. Differentials

10) Remove the hypoid driven gear by loosening hypoid driven gear bolts.

Subaru Outback. Differentials

11) Remove the pinion shaft lock pin from hypoid driven gear side using ST.

ST 899904100 STRAIGHT PIN REMOVER

Subaru Outback. Differentials

12) Draw out the pinion mate shaft, and remove pinion mate gears, pinion mate gear washers, side gears, and thrust washers.

NOTE: The gears and washers should be marked with RH or LH, front or rear, or kept separately.

Subaru Outback. Differentials

  1. Side gear
  2. Pinion mate gear
  3. Side gear thrust washer
  4. Differential case
  5. Pinion mate shaft
  6. Pinion mate gear washer

13) Remove the self-locking nut while securing the companion flange with ST.

ST 498427200 FLANGE WRENCH

Subaru Outback. Differentials

14) Extract the companion flange with a puller.

Subaru Outback. Differentials

  1. Companion flange
  2. Puller

15) Press the end of drive pinion shaft using ST and remove the rear bearing cone, preload adjusting spacer and washer.

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

ST 398467700 DRIFT

Subaru Outback. Differentials

16) Remove the rear bearing cone from drive pinion by supporting the cone with ST.

NOTE: Place the replacer so that its center-recessed side faces the bearing cone.

ST 398517700 REPLACER

Subaru Outback. Differentials

17) Remove the front oil seal from differential carrier using ST.

ST 398527700 PULLER ASSY

Subaru Outback. Differentials

  1. Differential carrier
  2. Front oil seal

18) Remove the pilot bearing together with the front bearing cone and spacer using the ST.

ST 398467700 DRIFT

Subaru Outback. Differentials

  1. Pilot bearing
  2. Spacer
  3. Front bearing
  4. Rear bearing race

19) When replacing the bearings, use a brass bar to tap out the front bearing race and rear bearing race in this order to remove them.

Subaru Outback. Differentials

  1. 2 cutout portions along diagonal lines
  2. Tap alternately with brass bar.

D: ASSEMBLY

NOTE:

Subaru Outback. Differentials

1) Adjusting preload for front and rear bearings NOTE: Adjust the bearing preload between front and rear bearings with preload adjusting spacer and washer.

Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted.

  1. Install the rear bearing race into the differential carrier using ST1 and ST2.

ST1 398477701 HANDLE
ST2 398477703 DRIFT 2

Subaru Outback. Differentials

  1. Install the front bearing race to the differential carrier using ST1 and ST2.

ST1 398477701 HANDLE
ST2 398477702 DRIFT

  1. Insert ST1 into the differential carrier with the pinion height adjusting washer and rear bearing cone fitted onto it.

NOTE:

  1. Install the preload adjusting spacer and washer, front bearing cone, ST2, companion flange and self-locking nut.

ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR

Subaru Outback. Differentials

  1. Pinion height adjusting washer
  2. Preload adjusting spacer
  3. Preload adjusting washer
  1. Turn the ST1 by hand to smooth the bearing, and tighten the self-locking nut while measuring the initial load or initial torque with a spring scale or torque wrench. Select the preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque.

NOTE:

ST1 398507702 DUMMY SHAFT
ST2 398507704 BLOCK

Tightening torque: 181.5 N*m (18.5 kgf-m, 133.9 ft-lb)

Subaru Outback. Differentials

Initial load: 18.1 - 38.8 N (1.8 - 4.0 kgf, 4.1 - 8.7 lbf)

Subaru Outback. Differentials

Initial torque: 0.69 - 1.47 N*m (0.07 - 0.15 kgf-m, 0.51 - 1.08 ft-lb)

Subaru Outback. Differentials

Subaru Outback. Differentials

2) Adjusting drive pinion height: Adjust the drive pinion height with pinion height adjusting washer installed between the rear bearing cone and the back of pinion gear.

  1. Attach the ST2.

NOTE: At this time, install a provisionally selected or previously used pinion height adjusting washer. Measure and record the thickness.

ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER GAUGE
ST3 398507703 DUMMY COLLAR

Subaru Outback. Differentials

  1. Pinion height adjusting washer
  1. Measure the clearance "N" between the end of ST2 and the end surface of ST1 by using a thickness gauge.

NOTE: Make sure there is no clearance between the differential carrier and ST2.

ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER GAUGE

Subaru Outback. Differentials

  1. Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed washer with this one.

T = To + N - (H × 0.01) - 0.20 mm (0.0079 in)

Subaru Outback. Differentials

(Example of calculation)
To = 3.39 mm (0.1335 in)
N = 0.24 mm (0.0094 in)
H = + 1
T = 3.39 mm (0.1335 in) + 0.24 mm (0.0094 in)
- 0.01 mm (0.0004 in) - 0.20 mm (0.0079 in) = 3.42 mm (0.1346 in)
Result: Thickness = 3.42 mm (0.1346 in)
Therefore use washer 383605200.

Subaru Outback. Differentials

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

ST 398177700 INSTALLER

Subaru Outback. Differentials

4) Insert the drive pinion into the differential carrier, and install the preselected preload adjusting spacer and washer.

Subaru Outback. Differentials

  1. Drive pinion
  2. Preload adjusting spacer
  3. Preload adjusting washer
  4. Differential carrier

5) Press-fit the front bearing cone with ST1, ST2 and ST3.

ST1 398507703 DUMMY COLLAR
ST2 399780104 WEIGHT
ST3 899580100 INSTALLER

Subaru Outback. Differentials

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

ST1 399780104 WEIGHT
ST2 899580100 INSTALLER

Subaru Outback. Differentials

7) Using the ST, install the oil seal.

NOTE:

ST 498447120 INSTALLER

Subaru Outback. Differentials

8) Press-fit the companion flange with ST1 and ST2.

NOTE: Be careful not to damage the bearing.

ST1 899874100 INSTALLER
ST2 399780104 WEIGHT

Subaru Outback. Differentials

9) Apply seal material on the drive pinion shaft thread and new self-locking nut seat.

Seal material: THREE BOND 1324 (Part No. 004403042) or equivalent

10) Attach the new self-locking nut and use the ST to fix the companion flange in place, then tighten the self-locking nut.

Tightening torque: 181.5 N*m (18.5 kgf-m, 133.9 ft-lb)

ST 498427200 FLANGE WRENCH

Subaru Outback. Differentials

11) Check the initial torque or initial load.

Initial load: 18.1 - 38.8 N (1.8 - 4.0 kgf, 4.1 - 8.7 lbf)

Subaru Outback. Differentials

Initial torque: 0.69 - 1.47 N*m (0.07 - 0.15 kgf-m, 0.51 - 1.08 ft-lb)

Subaru Outback. Differentials

12) Assembling differential case

Install the side gears and pinion mate gears, with their side gear thrust washers, pinion mate gear washer, and pinion mate shaft, into the differential case.

NOTE:

Subaru Outback. Differentials

  1. Measure the side gear backlash.

Side gear backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)

Subaru Outback. Differentials

  1. Adjust the backlash as specified by selecting side gear thrust washer.

Subaru Outback. Differentials

  1. Check the condition of rotation after applying oil to the gear tooth surfaces and thrust washer surfaces.
  2. Drive the pinion shaft lock pin into the differential case.

13) Install the driven gear to the differential case.

NOTE:

Seal material: THREE BOND 1324 (Part No. 004403042) or equivalent

Tightening torque: 103 N*m (10.5 kgf-m, 76.0 ft-lb)

Subaru Outback. Differentials

14) Using the ST, press-fit the side bearing to the differential case.

ST 398487700 DRIFT

Subaru Outback. Differentials

15) Using the ST, press-fit the side bearing outer race to the side retainer.

CAUTION: Make sure that the bearing outer races and cones are properly assembled.

ST 398417700 DRIFT

Subaru Outback. Differentials

16) Side retainer shim adjustment

  1. The hypoid driven gear backlash and side bearing preload can be adjusted by the side retainer shim thickness.
  2. Install the differential case assembly into differential carrier in the reverse order of disassembly.

NOTE: Be careful not to hit the teeth of hypoid driven gear against the differential carrier.

Subaru Outback. Differentials

  1. Install the side retainer shim.

NOTE:

Subaru Outback. Differentials

  1. Align the arrow mark on the differential carrier with the arrow mark on the side retainer when installing the side retainer.

NOTE: Be careful that the side bearing outer race is not damaged by the bearing roller.

Subaru Outback. Differentials

  1. Arrow mark (on the side retainer)
  2. Arrow mark (on the differential carrier)
  1. Tighten the side retainer bolts.

Tightening torque: 10.5 N*m (1.1 kgf-m, 7.7 ft-lb)

Subaru Outback. Differentials

  1. Measure the hypoid driven gear to drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of hypoid driven gear, and move hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge. If the backlash is outside the standard range, adjust the side retainer shim by the following method.

Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)

Subaru Outback. Differentials

  1. Measure the total preload of the drive pinion.

    If the total preload is outside the specification range, adjust the thickness of side retainer shims, increasing/reducing both shims by an even amount at a time.

Total preload: 20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7 - 12.2 lbf)

17) Recheck the hypoid driven gear to drive pinion backlash.

Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)

Subaru Outback. Differentials

18) Check pinion and hypoid driven gears rotate smoothly and make sure of the hypoid driven gear runout on its back surface. If the hypoid driven gear runout on its back surface exceeds the specification, check for any foreign objects between the hypoid driven gear and differential case, and for any deformation of the differential case or hypoid driven gear.

Hypoid driven gear back surface runout: 0.05 mm (0.002 in)

Subaru Outback. Differentials

19) Check and adjustment of the tooth contact of hypoid driven gear and drive pinion

  1. Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Check the contact pattern after rotating the hypoid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear.
  2. When the contact pattern is not correct, readjust.

NOTE: Be sure to wipe off the lead-free red dye completely after the adjustment is completed.

Check item: Tooth contact pattern is slightly shifted toward toe side under no-load rotation.

(When driving, it moves towards the heel side.)

Subaru Outback. Differentials

  1. Toe side
  2. Heel side

Check item: Backlash is too large.

Contact pattern

Subaru Outback. Differentials

Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.

Subaru Outback. Differentials

Check item: Backlash is too small.

Contact pattern

Subaru Outback. Differentials

Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.

Subaru Outback. Differentials

Check item: Teeth contact area is too small.

Contact pattern

Subaru Outback. Differentials

Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.

Subaru Outback. Differentials

Check item: Teeth contact area is too small.

Contact pattern

Subaru Outback. Differentials

Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.

Subaru Outback. Differentials

20) If proper tooth contact is not obtained, readjust the drive pinion height by changing the RH and LH side retainer shims and the hypoid gear backlash.

  1. Drive pinion height

ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER GAUGE

Subaru Outback. Differentials

T = To + N - (H × 0.01) - 0.20 mm (0.0079 in)

Subaru Outback. Differentials

  1. Hypoid gear backlash

Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)

Subaru Outback. Differentials

21) Remove the RH and LH side retainers.

22) Install the O-ring to left and right side retainers.

NOTE: Use new O-rings.

23) Install the oil seal to the side retainer of both sides. <Ref. to DI-78, REPLACEMENT, Rear Differential Side Oil Seal.>

24) Align the arrow mark on the differential carrier with the arrow mark on the side retainer when installing the side retainer.

Subaru Outback. Differentials

  1. Arrow mark (on the side retainer)
  2. Arrow mark (on the differential carrier)

25) Apply liquid gasket to the bolts indicated by arrows, and tighten the bolts.

Liquid gasket: THREE BOND 1110B (Part No. K0879Y0020) or equivalent

Tightening torque: 10.5 N*m (1.1 kgf-m, 7.7 ft-lb)

Subaru Outback. Differentials

26) Install the gasket and rear cover, and tighten the bolts to specified torque.

NOTE: Use a new gasket.

Tightening torque: 29.5 N*m (3.0 kgf-m, 21.8 ft-lb)

Subaru Outback. Differentials

27) Install the air breather cap.

NOTE: When installing the air breather cap, do not tap section (A). Be sure to tap section (B) to install.

Subaru Outback. Differentials

28) Install the drain plug.

NOTE: Apply liquid gasket to the drain plug.

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

Tightening torque: 49 N*m (5.0 kgf-m, 36.1 ft-lb)

29) Install the filler plug.

NOTE: After installing the rear differential assembly to the vehicle, fill the gear oil, then apply liquid gasket, and tighten to the specified torque. <Ref. to DI-23, REPLACEMENT, Differential Gear Oil.>

E: INSPECTION

Wash all the disassembled parts clean, and examine them for wear, damage and other defects. Repair or replace the defective parts as necessary.

1) Hypoid driven gear and drive pinion

2) Side gear and pinion mate gear

3) Bearing

4) Thrust washer of the side gear and pinion mate gear

5) Oil seal

6) Differential carrier

7) Differential case

8) Companion flange

1. SIDE GEAR BACKLASH

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

Side gear backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)

If the side gear backlash is not within the specification, select the side gear thrust washer and adjust the side gear backlash as specified.

Subaru Outback. Differentials

2. HYPOID DRIVEN GEAR BACKLASH

Using a dial gauge, check the backlash of hypoid driven gear.

Hypoid driven gear backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)

If the hypoid driven gear backlash is outside the specification range, adjust the side bearing preload and repair if necessary.

Subaru Outback. Differentials

3. HYPOID DRIVEN GEAR RUNOUT ON ITS BACK SURFACE

Using a dial gauge, check the hypoid driven gear back surface runout.

Hypoid driven gear back surface runout: 0.05 mm (0.002 in)

If the hypoid driven gear runout on its back surface exceeds the limit, replace the hypoid driven gear.

Subaru Outback. Differentials

4. TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION

Inspect the tooth contact between the hypoid driven gear and drive pinion. <Ref. to DI-32, ASSEMBLY, Rear Differential (T-type).>

5. TOTAL PRELOAD

Using a spring scale, check the total preload.

Total preload: 20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7 - 12.2 lb)

If the total preload is not within the specification, adjust the side retainer shim.

Subaru Outback. Differentials

6. COMPANION FLANGE

1) If rust or dirt is attached to the companion flange, remove them.

2) Set a dial gauge at a companion flange surface (mating surface of propeller shaft and companion flange), and then measure the companion flange runout.

Limit of runout: 0.08 mm (0.003 in)

Subaru Outback. Differentials

3) Set the gauge inside of the companion flange, and measure the runout.

Limit of runout: 0.08 mm (0.003 in)

Subaru Outback. Differentials

4) If either runout exceeds the limit, move the phase of companion flange and drive pinion 90º each, and find the point where the runout is within the limit.

5) If the runout exceeds the limit even after changing the phase, replace the companion flange and recheck the runout.

6) If the runout exceeds the limit after replacing the companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.

F: ADJUSTMENT

1. SIDE GEAR BACKLASH

Adjust the side gear backlash. <Ref. to DI-32, ASSEMBLY, Rear Differential (T-type).>

2. HYPOID DRIVEN GEAR BACKLASH

Adjust hypoid driven gear backlash. <Ref. to DI-32, ASSEMBLY, Rear Differential (T-type).>

3. TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION

Adjust the tooth contact between hypoid driven gear and drive pinion gear. <Ref. to DI-32, ASSEMBLY, Rear Differential (T-type).>

4. TOTAL PRELOAD

Adjust the side retainer shim. <Ref. to DI-32, ASSEMBLY, Rear Differential (T-type).>

READ NEXT:

 Rear Differential (VA-type)

A: REMOVAL The removal procedure for VA-type is included in "REMOVAL" for T-type. <Ref. to DI-26, REMOVAL, Rear Differential (T-type).> B: INSTALLATION The installation procedure for VA-type is

 Rear Differential Front Oil Seal

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A: INSPECTION Check the rear differential mount bushing for cracks, hardening or damage. If cracking, hardening or damage is excessive, replace rear differential mount bushing. B: REPLACEMENT CAUTION:

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