Subaru Outback manuals

Subaru Outback: 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 included in "INSTALLATION" for T-type. <Ref. to DI-28, INSTALLATION, Rear Differential (T-type).>

C: DISASSEMBLY

1. VA1-TYPE

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 rear cover by removing retaining bolts.

NOTE: Remove it by tapping with a plastic hammer.

Subaru Outback. Differentials

4) Remove the air breather cap.

NOTE:

Subaru Outback. Differentials

  1. Air breather cap
  2. Rear cover

5) Remove the lock plate RH and LH.

Subaru Outback. Differentials

6) Remove the side retainer RH and LH with ST.

NOTE: When keeping the retainers aside, use labels etc. to avoid confusing the left and right.

ST 18630AA010 WRENCH COMPL RETAINER

Subaru Outback. Differentials

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

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

Subaru Outback. Differentials

8) Remove the bearing race from side retainer RH and LH with ST1 and ST2.

ST1 499705401 PULLER ASSY
ST2 499705404 SEAT

Subaru Outback. Differentials

  1. Bearing race
  2. Side retainer

9) Remove the oil seal from the RH and LH side retainers using a screwdriver.

NOTE: Perform this operation only when changing oil seal.

Subaru Outback. Differentials

10) Extract the bearing cone with ST1 and ST2.

NOTE:

ST1 899524100 PULLER SET
ST2 399520105 SEAT

Subaru Outback. Differentials

11) Using the ST, loosen the hypoid driven gear bolt and remove the hypoid driven gear.

ST 18270KA020 SOCKET (E20)

Subaru Outback. Differentials

12) Remove the spring pin from hypoid driven gear side using ST.

ST 899904100 STRAIGHT PIN REMOVER

Subaru Outback. Differentials

13) Draw out the pinion mate shaft and remove pinion mate gears, 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. Thrust washer
  4. Differential case
  5. Pinion mate shaft

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

ST 498427200 FLANGE WRENCH

Subaru Outback. Differentials

15) Extract the companion flange with a puller.

Subaru Outback. Differentials

  1. Companion flange
  2. Puller

16) Press the end of drive pinion shaft and extract it together with rear bearing cone, pinion height adjusting washer and washer by using the ST.

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

ST 398467700 DRIFT

Subaru Outback. Differentials

17) 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 498515500 REPLACER

Subaru Outback. Differentials

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

ST 398527700 PULLER ASSY

Subaru Outback. Differentials

  1. Differential carrier
  2. Front oil seal

19) 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 cup

20) When replacing the bearings, hit out the front bearing cup and rear bearing cup in this order using a brass bar.

Subaru Outback. Differentials

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

2. VA2-TYPE

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 rear cover by removing retaining bolts.

NOTE: Remove it by tapping with a plastic hammer.

Subaru Outback. Differentials

4) Remove the air breather cap.

NOTE:

Subaru Outback. Differentials

  1. Air breather cap
  2. Rear cover

5) Remove the lock plate RH and LH.

Subaru Outback. Differentials

6) Remove the side retainer RH and LH with ST.

NOTE: When keeping the retainers aside, use labels etc. to avoid confusing the left and right.

ST 18630AA010 WRENCH COMPL RETAINER

Subaru Outback. Differentials

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

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

Subaru Outback. Differentials

8) Remove the bearing race from side retainer RH and LH with ST and the press.

NOTE:

ST 18758AA000 PULLER

Subaru Outback. Differentials

  1. Groove
  2. Claw

Subaru Outback. Differentials

  1. Side retainer

9) Remove the oil seal from the RH and LH side retainers using a screwdriver.

NOTE: Perform this operation only when changing oil seal.

Subaru Outback. Differentials

10) Extract the bearing cone with ST1, ST2 and ST3.

NOTE:

ST1 498077000 REMOVER
ST2 399520105 SEAT
ST3 899864100 REMOVER

Subaru Outback. Differentials

11) Using the ST, loosen the hypoid driven gear bolt and remove the hypoid driven gear.

ST 18270KA020 SOCKET (E20)

Subaru Outback. Differentials

12) Remove the spring pin from hypoid driven gear side using ST.

ST 899904100 STRAIGHT PIN REMOVER

Subaru Outback. Differentials

13) Draw out the pinion mate shaft and remove pinion mate gears, 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. Thrust washer
  4. Differential case
  5. Pinion mate shaft

14) Remove the circlip from the side gear.

Subaru Outback. Differentials

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

ST 498427200 FLANGE WRENCH

Subaru Outback. Differentials

16) Extract the companion flange using a puller.

Subaru Outback. Differentials

  1. Companion flange
  2. Puller

17) Remove the drive pinion shaft.

18) 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

19) Remove the front oil seal from differential carrier using screwdriver.

20) Remove the pilot bearing, front bearing cone and spacer.

Subaru Outback. Differentials

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

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

Subaru Outback. Differentials

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

D: ASSEMBLY

1. VA1-TYPE

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 be carried out with oil seal removed.

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

ST1 398477701 HANDLE
ST2 398477702 DRIFT

Subaru Outback. Differentials

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

ST1 398477701 HANDLE
ST2 498447110 DRIFT

  1. Insert the front bearing cone.

NOTE: Use new front bearing cone.

  1. Measure and record the thickness of pinion height adjusting washer.

NOTE: If tooth contact (drive pinion and hypoid driven gear) is normal in the inspection before disassembling, verify that the washer is not deformed, and then reuse the used washer.

  1. Insert the ST (DUMMY SHAFT) into case with the pinion height adjusting washer and rear bearing cone fitted onto it.

NOTE: Use new rear bearing cone.

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

ST 498447150 DUMMY SHAFT
Part No. 32285AA000 Spacer

Subaru Outback. Differentials

  1. Pinion height adjusting washer
  2. Preload adjusting spacer
  3. Preload adjusting washer
  4. Spacer (SUBARU genuine parts)
  1. Turn the ST by hand to slowly seat 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 498447150 DUMMY SHAFT
ST2 398507704 BLOCK

Tightening torque: 191 N*m (19.5 kgf-m, 140.9 ft-lb)

Subaru Outback. Differentials

Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lbf)

Subaru Outback. Differentials

Initial torque: 0.48 - 1.22 N*m (0.05 - 0.12 kgf-m, 0.35 - 0.90 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.

ST1 498447150 DUMMY SHAFT
ST2 498505501 DIFFERENTIAL CARRIER GAUGE
Part No. 32285AA000 Spacer

Subaru Outback. Differentials

  1. Pinion height adjusting washer
  2. Spacer (SUBARU genuine parts)
  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 498447150 DUMMY SHAFT
ST2 498505501 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.

NOTE: Adjust it using the 1 - 3 washers.

T = To + N - 0.05 mm (0.0020 in)

Subaru Outback. Differentials

(Example of calculation)
To = 0.15 mm (0.0059 in)
N = 0.1 mm (0.0039 in)
T = 0.15 + 0.1 - 0.05 = 0.2 mm (0.0079 in)
Result: Thickness = 0.2 mm (0.0079 in)
Therefore use part number 32295AA220.

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 498175500 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 into the carrier with ST1, ST2 and the spacer.

ST1 399780104 WEIGHT
ST2 899580100 INSTALLER
Part No. 32285AA000 Spacer

Subaru Outback. Differentials

  1. Spacer (SUBARU genuine parts)

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 pilot bearing.

ST1 899874100 INSTALLER
ST2 399780104 WEIGHT

Subaru Outback. Differentials

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

NOTE:

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

Tightening torque: 191 N*m (19.5 kgf-m, 140.9 ft-lb)

ST 498427200 FLANGE WRENCH

Subaru Outback. Differentials

10) Check the initial torque or initial load.

Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lbf)

Subaru Outback. Differentials

Initial torque: 0.48 - 1.22 N*m (0.05 - 0.12 kgf-m, 0.35 - 0.90 ft-lb)

Subaru Outback. Differentials

11) Assembling differential case

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

NOTE:

Subaru Outback. Differentials

  1. Measure the side gear backlash.

Side gear backlash: 0.05 - 0.15 mm (0.002 - 0.006 in)

Subaru Outback. Differentials

  1. Adjust the side gear backlash 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 spring pin into the differential case.

NOTE: Use new spring pin.

12) Install the hypoid driven gear to differential case.

NOTE:

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

  1. Tighten the hypoid driven gear mounting bolts to the specified torque using the ST.

ST 18270KA020 SOCKET (E20)

Tightening torque: 20 N*m (2.0 kgf-m, 14.8 ft-lb)

Subaru Outback. Differentials

  1. While checking the tightening angle with the ST, further tighten the hypoid driven gear mounting bolts.

Tightening angle: 35º+-2º

ST 18554AA000 ANGLE GAUGE

Subaru Outback. Differentials

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

ST 498485400 DRIFT

Subaru Outback. Differentials

14) Assemble the side retainer.

  1. Install the oil seal into side retainer RH and LH.

CAUTION: Pay attention to the left and right of the oil seal.

NOTE: Use a new oil seal.

ST 498447100 INSTALLER

Subaru Outback. Differentials

  1. Install the bearing race into side retainer RH and LH.

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

ST 398477702 DRIFT

Subaru Outback. Differentials

  1. 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. Temporally tighten the side retainers RH and LH in differential carrier to install.

15) Perform the backlash adjustment between the hypoid driven gear and drive pinion, and preload adjustment of differential side bearing.

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

ST 498427200 FLANGE WRENCH

Subaru Outback. Differentials

  1. Using the ST, tighten side retainer RH, and then tighten side retainer LH until there is no backlash.

ST 18630AA010 WRENCH COMPL RETAINER

Subaru Outback. Differentials

  1. Loosen the side retainer LH by approx. 1 and 1/2 teeth, and tighten the side retainer RH by approx. 2 teeth [amount that the side retainer LH is turned back (1 and 1/2) + approx. 0.5 teeth]. Difference between [amount that the side retainer LH is turned back (approx. 1 and 1/2 teeth) ] and [amount that the side retainer RH is tightened (approx. 2 teeth) ] gives preload.
  2. Temporarily tighten the lock plate.

NOTE: Turn over the lock plate to shift the holder by 1/2 tooth.

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.

NOTE: If measured value of backlash is not within the specified range, repeat the procedures for pinion driven gear set backlash adjustment and the differential side bearing preload adjustment.

Backlash: 0.10 - 0.15 mm (0.004 - 0.006 in)

Subaru Outback. Differentials

16) Put alignment marks on both the differential carrier and side retainer. Remove the side retainers one side at a time. After installing an O-ring and applying oil to the threaded portion, restore them to the original position.

Subaru Outback. Differentials

  1. Alignment mark
  2. Side retainer

17) Install the lock plate, and tighten the bolts to the specified torque.

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

Subaru Outback. Differentials

18) Recheck the backlash between hypoid driven gear and drive pinion.

Backlash: 0.10 - 0.15 mm (0.004 - 0.006 in)

Subaru Outback. Differentials

19) Checking and adjusting the tooth contact of hypoid driven gear

  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 side.

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 correct tooth contact is not obtained, readjust the drive pinion height and the differential side bearing preload (already mentioned) and the hypoid gear backlash.

21) Install the gasket and rear cover to the differential carrier, and tighten the bolts to specified torque.

NOTE: Use a new gasket.

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

Subaru Outback. Differentials

  1. Rear cover

22) 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

23) Install the drain plug.

NOTE: Use a new gasket.

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

24) Install the filler plug.

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

2. VA2-TYPE

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. Using the ST, press-fit the front bearing race to the differential carrier.

ST 499277200 INSTALLER

Subaru Outback. Differentials

  1. Insert the front bearing cone.

NOTE: Use new front bearing cone.

  1. Measure and record the thickness of the pinion height adjusting washer.

NOTE: If tooth contact (drive pinion and hypoid driven gear) is normal in the inspection before disassembling, verify that the washer is not deformed, and then reuse the used washer.

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

NOTE: Use new rear bearing cone.

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

ST1 18678AA000 DUMMY SHAFT

Subaru Outback. Differentials

  1. Pinion height adjusting washer 0.90 ft-lb)
  2. Preload adjusting spacer
  3. Preload adjusting washer
  4. Spacer
  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 18678AA000 DUMMY SHAFT
ST2 498427200 FLANGE WRENCH

Tightening torque: 191 N*m (19.5 kgf-m, 140.9 ft-lb)

Subaru Outback. Differentials

Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lbf)

Subaru Outback. Differentials

Initial torque: 0.48 - 1.22 N*m (0.05 - 0.12 kgf-m, 0.35 - 0.90 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.

ST1 18678AA000 DUMMY SHAFT
ST2 18831AA010 DIFFERENTIAL CARRIER GAUGE

Subaru Outback. Differentials

  1. Pinion height adjusting washer
  1. Install the side retainer LH to the left side of the differential carrier in reverse direction.

Subaru Outback. Differentials

  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 18678AA000 DUMMY SHAFT
ST2 18831AA010 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.

NOTE: Adjust it using the 1 - 3 washers.

T = To + N - 0.05 mm (0.0020 in)

Subaru Outback. Differentials

(Example of calculation)
To = 0.15 mm (0.0059 in)
N = 0.1 mm (0.0039 in)
T = 0.15 mm (0.0059 in) + 0.1 mm (0.0039 in) - 0.05 mm (0.0020 in) = 0.2 mm (0.0079 in)
Result: Thickness = 0.2 mm (0.0079 in)
Therefore use part number 32295AA370.

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) Set ST and differential carrier to the press and install the front bearing cone.

ST 399780104 WEIGHT NOTE: Set the carrier to the press until the companion flange is installed.

Subaru Outback. Differentials

6) Insert the spacer, then install the pilot bearing.

Subaru Outback. Differentials

  1. Pilot bearing
  2. Spacer

7) Using the ST, install the oil seal.

NOTE:

Subaru Outback. Differentials

8) Press-fit the companion flange with ST.

NOTE: Be careful not to damage the bearing.

ST 899874100 INSTALLER

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) Install the self-locking nut while holding the companion flange with ST.

Tightening torque:
191 N*m (19.5 kgf-m, 140.9 ft-lb)
ST 498427200 FLANGE WRENCH

Subaru Outback. Differentials

11) Check the initial torque or initial load.

Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lbf)

Subaru Outback. Differentials

Initial torque: 0.48 - 1.22 N*m (0.05 - 0.12 kgf-m, 0.35 - 0.90 ft-lb)

Subaru Outback. Differentials

12) Assembling differential case

  1. Attach the circlip to the side gear.

Subaru Outback. Differentials

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

NOTE:

Subaru Outback. Differentials

  1. Measure the side gear backlash.

Side gear backlash: 0.13 - 0.18 mm (0.005 - 0.007 in)

Subaru Outback. Differentials

  1. Adjust the side gear 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. Attach the spring pin to the differential case.

NOTE: Use new spring pin.

13) Install the hypoid driven gear to differential case.

NOTE:

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

  1. Tighten the hypoid driven gear mounting bolts to the specified torque using the ST.

ST 18270KA020 SOCKET (E20)

Tightening torque: 20 N*m (2.0 kgf-m, 14.8 ft-lb)

Subaru Outback. Differentials

  1. While checking the tightening angle with the ST, further tighten the hypoid driven gear mounting bolts.

Tightening angle: 33º+-2º

ST 18554AA000 ANGLE GAUGE

Subaru Outback. Differentials

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

ST 398487700 DRIFT

Subaru Outback. Differentials

15) Assemble the side retainer.

  1. Install the oil seal into side retainer RH and LH.

NOTE: Use a new oil seal.

ST 498447100 INSTALLER

Subaru Outback. Differentials

  1. Install the bearing race into side retainer RH and LH.

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

ST 398417700 DRIFT

Subaru Outback. Differentials

  1. 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. Temporally tighten the side retainers RH and LH in differential carrier to install.

16) Perform the backlash adjustment between the hypoid driven gear and drive pinion, and side bearing preload adjustment.

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

ST 498427200 FLANGE WRENCH

Subaru Outback. Differentials

  1. Using the ST, tighten side retainer RH, and then tighten side retainer LH until there is no backlash.

ST 18630AA010 WRENCH COMPL RETAINER

Subaru Outback. Differentials

  1. Back off the side retainer LH by approx. 1.5 teeth, and tighten the side retainer RH by approx. 2 teeth [amount that the side retainer LH is turned back (1.5) + 1/2 teeth].

NOTE: Difference between [amount that the side retainer LH is turned back (approx. 1 and 1/2 teeth) ] and [amount that the side retainer RH is tightened (approx. 2 teeth) ] gives preload.

  1. Temporarily attach the lock plate.

NOTE: Turn over the lock plate to shift the holder by 1/2 teeth.

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.

NOTE: If measured value of backlash is not within the specified range, repeat the procedures for the backlash adjustment between hypoid driven gear and drive pinion, and the differential side bearing preload adjustment.

Backlash: 0.10 - 0.15 mm (0.004 - 0.006 in)

Subaru Outback. Differentials

17) Put alignment marks on both the differential carrier and side retainer. Remove the side retainers one side at a time. After installing an O-ring and applying differential gear oil to the threaded portion, restore them to the original position.

Subaru Outback. Differentials

  1. Alignment mark
  2. Side retainer

18) Tighten the bolt of lock plate to specified torque.

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

Subaru Outback. Differentials

19) Recheck the hypoid driven gear to pinion backlash.

Backlash: 0.10 - 0.15 mm (0.004 - 0.006 in)

Subaru Outback. Differentials

20) Checking and adjusting the tooth contact of hypoid driven gear

  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

21) If correct tooth contact is not obtained, readjust the drive pinion height and the differential side bearing preload (already mentioned) and the hypoid gear backlash.

22) Install the gasket and rear cover to the differential carrier, and tighten the bolts to specified torque.

NOTE: Use a new gasket.

Tightening torque: 34 N*m (3.5 kgf-m, 25.1 ft-lb)

Subaru Outback. Differentials

23) 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

24) Install the drain plug.

NOTE: Use a new gasket.

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

25) Install the filler plug.

NOTE: After installing the rear differential assembly to the vehicle, fill the gear oil, then use a new 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 or 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

Replace if seizure, peeling, wear, rust, dragging during rotation, noise or other defect is evident.

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

Replace if seized, flawed, abnormally worn or having other defects.

5) Oil seal

Replace if deformed or damaged, and at every disassembling.

6) Differential carrier

Replace if the bearing bores are worn or damaged.

7) Differential case

Replace if its sliding surfaces are abnormally worn, burned, or cracked.

8) Companion flange

Replace if the oil seal lip contact surface shows cracking.

1. SIDE GEAR BACKLASH

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

Side gear backlash:
VA1-type:
0.05 - 0.15 mm (0.002 - 0.006 in)
VA2-type:
0.13 - 0.18 mm (0.005 - 0.007 in)

If the side gear backlash is outside the specification range, 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 - 0.15 mm (0.004 - 0.006 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. 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.

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-52, ASSEMBLY, Rear Differential (VA-type).>

F: ADJUSTMENT

1. SIDE GEAR BACKLASH

Adjust the side gear backlash. <Ref. to DI-52, ASSEMBLY, Rear Differential (VA-type).>

2. HYPOID DRIVEN GEAR BACKLASH

Adjust hypoid driven gear backlash. <Ref. to DI-52, ASSEMBLY, Rear Differential (VA-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-52, ASSEMBLY, Rear Differential (VA-type).>

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