SERVICE DATA
| Front and rear bearing preload at companion flange bolt hole N (kgf, lb) | New bearing | 18.1 -38.8(1.8 - 4.0,4.1 -8.7) |
|---|---|---|
| Side gear backlash mm (in) | 0.10 - 0.20 (0.0039 - 0.0079) | |
| Side bearing standard width mm (in) | 20.00 (0.7874) | |
| Hypoid driven gear to drive pinion backlash mm (in) | 0.10 - 0.20 (0.0039 - 0.0079) | |
| Hypoid driven gear runout on its back surface mm (in) | Less than 0.05 (0.0020) | |
SERVICE DATA
ADJUSTING PARTS
| Drive pinion bearing preload (at companion flange bolt hole) | N (kgf, lb) | 18.1 -38.8 (1.8 - 4.0,4.1-8.7) | |
|---|---|---|---|
| Preload adjusting collar | Part No. | Length mm (in) | |
| 383695201 | 56.2(2.213) | ||
| 383695202 | 56.4 (2.220) | ||
| 383695203 | 56.6 (2.228) | ||
| 383695204 | 56.8 (2.236) | ||
| 383695205 | 57.0 (2.244) | ||
| 383695206 | 57.2 (2.252) | ||
| Preload adjusting washer | Part No. | Length mm (in) | |
| 383705200 | 2.59(0.1020) | ||
| 383715200 | 2.57(0.1012) | ||
| 383725200 | 2.55(0.1004) | ||
| 383735200 | 2.53 (0.0996) | ||
| 383745200 | 2.51 (0.0988) | ||
| 383755200 | 2.49 (0.0980) | ||
| 383765200 | 2.47 (0.0972) | ||
| 383775200 | 2.45 (0.0965) | ||
| 383785200 | 2.43 (0.0957) | ||
| 383795200 | 2.41 (0.0949) | ||
| 383805200 | 2.39(0.0941) | ||
| 383815200 | 2.37 (0.0933) | ||
| 383825200 | 2.35 (0.0925) | ||
| 383835200 | 2.33(0.0917) | ||
| 383845200 | 2.31 (0.0909) | ||
| Pinion height adjusting washer | Part No. | Thickness mm (in) | |
| 383495200 | 3.09(0.1217) | ||
| 383505200 | 3.12(0.1228) | ||
| 383515200 | 3.15(0.1240) | ||
| 383525200 | 3.18(0.1252) | ||
| 383535200 | 3.21 (0.1264) | ||
| 383545200 | 3.24(0.1276) | ||
| 383555200 | 3.27(0.1287) | ||
| 383565200 | 3.30(0.1299) | ||
| 383575200 | 3.33(0.1311) | ||
| 383585200 | 3.36(0.1323) | ||
| 383595200 | 3.39(0.1335) | ||
| 383605200 | 3.42(0.1346) | ||
| 383615200 | 3.45(0.1358) | ||
| 383625200 | 3.48(0.1370) | ||
| 383635200 | 3.51 (0.1382) | ||
| 383645200 | 3.54(0.1394) | ||
| 383655200 | 3.57(0.1406) | ||
| 383665200 | 3.60(0.1417) | ||
| 383675200 | 3.63(0.1429) | ||
| 383685200 | 3.66(0.1441) | ||
| Side gear backlash | Mm (in) | 0.1-0.2(0.0039 - 0.0079) | |
| Side gear thrust washer (Model without LSD) | Part No. | Thickness mm (in) | |
| 383445201 | 0.75 - 0.80 (0.0295 - 0.0315) | ||
| 383445202 | 0.80 - 0.85 (0.0315 - 0.0335) | ||
| 383445203 | 0.85 - 0.90 (0.0335 - 0.0354) | ||
| Side bearing standard width | Mm (in) | 20.00 (0.7874) | |
| Side bearing retainer shim | Part No. | Thickness mm (in) | |
| 383475201 | 0.20 (0.0079) | ||
| 383475202 | 0.25 (0.0098) | ||
| 383475203 | 0.30 (0.0118) | ||
| 383475204 | 0.40 (0.0157) | ||
| 383475205 | 0.50 (0.0197) | ||
| Hypoid driven gear to drive pinion backlash | Limit mm (in) | 0.10 - 0.20 (0.0039 - 0.0079) | |
| Hypoid driven gear runout on its back surface | 0.05 (0.0020) | ||
PARTS ADJUSTING SPECIFICATIONS
Scheme 114
Scheme 115
Scheme 116
CAUTION
- Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
- Remove contamination including dirt and corrosion before removal, installation or disassembly.
- Keep the disassembled parts in order and protect them from dust or dirt.
- Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
- Be careful not to burn your hands, because each part on the vehicle is hot after running.
- 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.
- Be sure to tighten fasteners including bolts and nuts to the specified torque.
- Place shop jacks or rigid racks at the specified points.
- Apply gear oil onto sliding or revolution surfaces before installation.
- Before installing O-rings or snap rings, apply sufficient amount of gear oil to avoid damage and deformation.
- 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.
- Avoid damaging the mating face of the case.
GENERAL TOOL
| TOOL NAME | REMARKS |
|---|---|
| Transmission jack | Used for assembly/disassembly of rear differential. |
| Puller | Used for removal of side bearing retainer. |
| Thickness gauge | Used for measuring clearance. |
| Hexagon wench | Used for installing and removing filter and drain plug. |
GENERAL TOOL SPECIFICATIONS
Scheme 117
- Take out the filler plug, and replace the gear oil if it is contaminated or deteriorated. < Ref. to «REPLACEMENT»(ref-274215-S32288685152007121400000) , Differential Gear Oil. >
- 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.
Scheme 118
Scheme 119
- Jack-up the vehicle and support it with sturdy racks.
- 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.
- Tighten the oil drain plug. NOTE: Apply liquid gasket to the drain plug. Liquid gasket: THREE BOND 1105 (Part number: 004403010) or equivalent Tightening torque: 49 N.m (5.0 kgf-m, 36.2 ft-lb)
- 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 lmp qt)
- Install the filler plug. NOTE: Apply liquid gasket to the filler plug. Liquid gasket: 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 of Automatic Transmission, refer to FRONT DIFFERENTIAL ASSEMBLY .
MT MODEL
For front differential of manual transmission, refer to FRONT DIFFERENTIAL ASSEMBLY .
Scheme 120
Scheme 121
Scheme 122
Scheme 123
Scheme 124
Scheme 125
Scheme 126
Scheme 127
Scheme 128
- Set the vehicle on a lift.
- Disconnect the ground cable from battery.
- Move the select lever or gear shift lever to "N".
- Release the parking brake.
- Loosen the wheel nuts.
- Jack-up the vehicle and support it with sturdy racks.
- Remove the wheels.
- Remove the rear exhaust pipe and muffler. Non-turbo model < Ref. to «REMOVAL»(ref-274158-S05380561552007121400000) , Rear Exhaust Pipe. > and < Ref. to «REMOVAL»(ref-274158-S42180220342007121400000) , Muffler. > Turbo model < Ref. to «REMOVAL»(ref-274159-S35889321872007121400000) , Rear Exhaust Pipe. > and < Ref. to «REMOVAL»(ref-274159-S11511559372007121400000) , Muffler. >
- Remove the propeller shaft. < Ref. to «REMOVAL»(ref-274216-S35906075402007121400000) , Propeller Shaft. >
- Remove the clamps and bracket of parking brake cable.
- Remove the DOJ of rear drive shaft from rear differential using ST. < Ref. to «REPLACEMENT»(ref-274215-S12060115792007121400000) , Rear Differential Side Oil Seal. > ST 28099PA100 DRIVE SHAFT REMOVER
- Secure the rear drive shaft to rear crossmember using wire.
- Remove the lower differential bracket.
- Support the rear differential with transmission jack.
- Remove the self-locking nuts and bolts.
- 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.
- Remove the bolt A.
- While slowly lowering the transmission jack, move the rear differential forward and remove front member and rear differential from body.
- Remove the rear differential from front member.
SIDE GEAR BACKLASH
Using a dial gauge, check the backlash of the side gear. (Model without LSD)
Side gear backlash
0.1 - 0.2 mm (0.0039 - 0.0079 in)
If the side gear backlash is not within the specification, adjust it as specified by selecting side gear thrust washer.
Scheme 129
HYPOID DRIVEN GEAR BACKLASH
Using a dial gauge, check the backlash of hypoid driven gear.
Hypoid driven gear backlash
0.1 - 0.2 mm (0.0039 - 0.0079 in)
If the hypoid driven gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.
Scheme 130
HYPOID DRIVEN GEAR RUNOUT ON ITS BACK SURFACE
Using a dial gauge, check the hypoid driven gear runout on its back surface.
Hypoid driven gear runout on its back surface: 0.05 mm (0.0020 in)
If the hypoid driven gear runout exceeds 0.05 mm (0.0020 in), replace the hypoid driven gear.
Scheme 131
TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between hypoid driven gear and drive pinion. < Ref. to ASSEMBLY , Rear Differential. >
TOTAL PRELOAD
Using a spring balance, 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 bearing retainer shims.
Scheme 132
Scheme 133
Scheme 134
- If rust or dirt is attached to the companion flange, remove them.
- 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 (0.0031 in)
- Set the gauge inside of the companion flange, and measure the runout. Limit of runout: 0.08 mm (0.0031 in)
- If either runout exceeds the limit, move the phase of companion flange and drive pinion 90° each, and find the point where the runout is within the limit.
- If the runout exceeds the limit after changing the phase, replace the companion flange and recheck the runout.
- If the runout exceeds the limit after replacing the companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.
Adjust the side gear backlash.
< Ref. to ASSEMBLY , Rear Differential. >
Adjust hypoid driven gear backlash.
< Ref. to ASSEMBLY , Rear Differential. >
Adjust the tooth contact between hypoid driven gear and drive pinion gear.
< Ref. to ASSEMBLY , Rear Differential. >
Adjust the side bearing shim.
< Ref. to ASSEMBLY , Rear Differential. >
Scheme 135
Scheme 136
Scheme 137
Scheme 138
Scheme 139
Scheme 140
- Set the vehicle on a lift.
- Disconnect the ground cable from battery.
- Move the select lever or gear shift lever to "N".
- Release the parking brake.
- Remove the oil drain plug, and drain the gear oil.
- Install the oil 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, 36.2 ft-lb)
- Lift up the vehicle.
- Remove the rear exhaust pipe and muffler. Non-turbo model < Ref. to «REMOVAL»(ref-274158-S05380561552007121400000) , Rear Exhaust Pipe. > and < Ref. to «REMOVAL»(ref-274158-S42180220342007121400000) , Muffler. > Turbo model < Ref. to «REMOVAL»(ref-274159-S35889321872007121400000) , Rear Exhaust Pipe. > and < Ref. to «REMOVAL»(ref-274159-S11511559372007121400000) , Muffler. >
- Remove the propeller shaft from body. < Ref. to «REMOVAL»(ref-274216-S35906075402007121400000) , Propeller Shaft. >
- Remove the self-locking nut while holding the companion flange with ST. ST 498427200 FLANGE WRENCH
- Extract the companion flange using ST. ST 399703600 PULLER ASSY
- Remove the oil seal using ST. ST 398527700 PULLER ASSY
- Fit a new oil seal using ST. NOTE: Apply oil to the outer surface of oil seal. ST 498447120 INSTALLER
- Install the companion flange. NOTE: Use a plastic hammer to install the companion flange.
- 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 Tightening torque: 181 N.m (18.5 kgf-m, 134 ft-lb)
- Hereafter, reassemble in the reverse order of disassembly.
- After installation, fill the differential carrier with gear oil to the filler plug level. < Ref. to «DIFFERENTIAL GEAR OIL»(ref-274215-S17216526722007121400000) . >