Differentials: Other Subaru Forester SG

SERVICE DATA

Service Data Specification

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CAUTION

1. Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust or dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
5. Be careful not to burn your hands, because each part on the vehicle is hot after running.
6. Use SUBARU genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with that of another grade or from other manufacturers.
7. Be sure to tighten fasteners including bolts and nuts to the specified torque.
8. Place shop jacks or safety stands at the specified points.
9. Apply gear oil onto sliding or revolution surfaces before installation.
10. Before installing O-rings or snap rings, apply sufficient amount of gear oil to avoid damage and deformation.
11. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise.
12. Avoid damaging the mating face of the case.

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1. Take out the filler plug, and replace the gear oil if it is contaminated or deteriorated. Refer to «REPLACEMENT»(ref-200799-S27656447932005102300000) , Differential Gear Oil.
2. Check the gear oil level is up to the bottom part of filler bolt. If the level is low, refill up to the bottom of filler bolt.

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1. Jack-up the vehicle and support it with sturdy racks.
2. Remove the oil drain plug and filler plug, and drain the gear oil. CAUTION: Be careful not to burn your hands, because gear oil becomes extremely hot after running.
3. Tighten the oil drain plug. NOTE: Apply fluid packing to the drain plug. Fluid packing: THREE BOND 1105 (Part number: 004403010) or equivalent Tightening torque: 49 N.m (5.0 kgf-m, 36.2 ft-lb)
4. Fill the differential carrier with gear oil to the upper plug level. NOTE: Carefully refill oil while watching the level. Excess or insufficient oil must be avoided. Oil capacity: 0.8 l (0.8 US qt, 0.7 Imp qt)
5. Install the filler plug. NOTE: Apply fluid packing to the filler plug. Fluid packing: THREE BOND 1105 (Part number: 004403010) or equivalent Tightening torque: 49 N.m (5.0 kgf-m, 36.2 ft-lb)

AT MODEL

For front differential, refer to FRONT DIFFERENTIAL .

MT MODEL

For front differential, refer to FRONT DIFFERENTIAL ASSEMBLY .

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1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Move the select lever or gear shift lever to "N".
4. Release the parking brake.
5. Loosen the wheel nuts.
6. Jack-up the vehicle and support it with sturdy racks.
7. Remove the wheels.
8. Remove the rear exhaust pipe and muffler. Refer to «REMOVAL»(ref-200789-S21679616402005102300000) , Rear Exhaust Pipe. «REMOVAL»(ref-200789-S31333937342005102300000) , Muffler.
9. Remove the propeller shaft.
10. Remove the clamps and bracket of parking brake cable.
11. Remove the DOJ of rear drive shaft from rear differential using ST, Refer to «REPLACEMENT»(ref-200799-S37428741292005102300000) , Rear Differential Side Oil Seal. ST 28099PA100 DRIVE SHAFT REMOVER
12. Secure the rear drive shaft to rear crossmember using wire.
13. Remove the lower differential bracket.
14. Support the rear differential with transmission jack.
15. Remove the self-locking nuts and bolts.
16. Remove the bolts which secure rear differential front member to body. Loosen the bolt A first, then remove the bolts B. NOTE: Support the front member with use of a helper to prevent it from dropping.
17. Remove the bolt A.
18. While slowly lowering the transmission jack, move the rear differential forward and remove front member and rear differential from body.
19. Remove the rear differential from front member.

SIDE GEAR BACKLASH

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

1. Side gear backlash: 0.1 - 0.2 mm (0.004 - 0.008 in)

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

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CROWN GEAR BACKLASH

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

1. Crown gear backlash: 0.1 - 0.2 mm (0.004 - 0.008 in)

If the crown gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.

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CROWN GEAR RUNOUT

Using a dial gauge, check the crown gear runout.

1. 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.

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TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION

Inspect the tooth contact between crown gear and driven pinion. Refer to ASSEMBLY , Rear Differential.

TOTAL PRELOAD

Using a gauge, check the turning resistance increase.

1. Turning resistance increase: 2.9 - 10.8 N (0.3 - 1.1 kgf, 0.7 - 2.4 lb)

If the increase of resistance is not within the specification, adjust the side bearing retainer shims.

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Adjust the side gear backlash.

Refer to ASSEMBLY , Rear Differential.

Adjust the crown gear backlash.

Refer to ASSEMBLY , Rear Differential.

Adjust the tooth contact between crown gear and drive pinion gear.

Refer to ASSEMBLY , Rear Differential.

Adjust the side bearing shim.

Refer to ASSEMBLY , Rear Differential.

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1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Move the select lever or gear shift lever to "N".
4. Release the parking brake.
5. Remove the oil drain plug, and drain the gear oil.
6. Install the oil drain plug. NOTE: Apply fluid packing to the drain plug. Tightening torque: 49 N.m (5.0 kgf-m, 36.2 ft-lb)
7. Jack-up the rear wheels and support the vehicle body with sturdy racks.
8. Remove the rear exhaust pipe and muffler.
9. Remove the propeller shaft from body.
10. Remove the self-locking nut while holding the companion flange with ST. ST 498427200 FLANGE WRENCH
11. Extract the companion flange using ST. ST 399703600 PULLER ASSY
12. Remove the oil seal using ST. ST 398527700 PULLER ASSY
13. Fit a new oil seal using ST. NOTE: Apply oil to the outer surface of oil seal. ST 498447120 INSTALLER
14. Install the companion flange. NOTE: Use a plastic hammer to install the companion flange.
15. Tighten the self-locking nut within the specified torque range so that the turning resistance of companion flange becomes the same as that before replacing oil seal. ST 498427200 FLANGE WRENCH NOTE: Use a new self-locking nut. Tightening torque: 181.5 N.m (18.5 kgf-m, 133.8 ft-lb)
16. Hereafter, reassemble in the reverse order of disassembly.