Differential System - Differentials: Diagnosis Subaru Forester SH

INSPECTION

1. Remove the filler plug, and then check the gear oil. Replace the gear oil if it is contaminated or deteriorated. Refer to «REPLACEMENT»(ref-325345-S35450896522009071800000) , Differential Gear Oil.
2. Check that the gear oil level is within -6 mm (-0.2 in) from the bottom of the filler plug hole. If the level is low, refill up to the bottom of filler plug.

Scheme 9

Scheme 10

Scheme 11

1. Lift up the vehicle.
2. Remove the oil drain plug and filler plug, and drain the gear oil. CAUTION: Gear oil is extremely hot just after driving. Be wary of receiving burns.
3. Tighten 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, 36.1 ft-lb)
4. Fill the differential carrier with gear oil to the bottom of filler plug. NOTE: Carefully refill oil while watching the level. Excessive or insufficient oil must be avoided. Recommended gear oil: Refer to «SPECIFICATION»(ref-325345-S31555792072009071800000) , General Description. Oil capacity: 0.8 l (0.8 US qt, 0.7 lmp qt)
5. Install the filler plug. NOTE: Apply liquid gasket to the filler plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent Tightening torque: 49 N.m (5.0 kgf-m, 36.1 ft-lb)

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 If there is evidently an abnormal tooth contact, find out the cause and adjust until the teeth contact correctly. Replace the gear if there is an excessive worn or an incapable adjustment. If crack, cutout or seizure is found, replace the parts as a set. Slight damage of some teeth can be corrected by oil stone or the like.
2. Side gear and pinion mate gear Replace if cracks, scoring or other defects are evident on the tooth surface. Replace if thrust washer contact surface is worn or seized. Slight damages of the surface can be corrected by oil stones or equivalent.
3. Bearing Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal 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.

Check that there is no leakage from front oil seal portion. If there is any leakage replace the oil seal and inspect the propeller shaft.

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Disconnect the ground cable from the battery.
2. Shift the select lever or gear shift lever to neutral.
3. Release the parking brake.
4. Remove the oil drain plug, and drain gear oil.
5. 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, 36.1 ft-lb)
6. Lift up the vehicle.
7. Remove the rear exhaust pipe and muffler. Non-turbo model Refer to «REMOVAL»(ref-325320-S35059142112009071800000) , Rear Exhaust Pipe. Refer to «REMOVAL»(ref-325320-S22382758332009071800000) , Muffler. Turbo model Refer to «REMOVAL»(ref-325336-S21151896522009071800000) , Rear Exhaust Pipe. Refer to «REMOVAL»(ref-325336-S04910540732009071800000) , Muffler.
8. Remove the heat shield cover.
9. Remove the propeller shaft. Refer to «REMOVAL»(ref-325313-S18232153912009071800000) , Propeller Shaft.
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 or screwdriver. ST 398527700 PULLER ASSY
13. Install a new oil seal using ST. NOTE: Apply differential gear oil to the oil seal lips. ST 498447120 INSTALLER
14. Install the companion flange. NOTE: Use a plastic hammer to install companion flange.
15. Tighten the self-locking nut to the specified torque so that rotating resistance of the companion flange becomes the same value as that before replacing the oil seal. ST 498427200 FLANGE WRENCH NOTE: Use a new self-locking nut. Before installing the self-locking nut, apply seal material to self-locking nut threads. SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) or equivalent Tightening torque: 181.5 N.m (18.5 kgf-m, 133.9 ft-lb)
16. Hereafter, reassemble in the reverse order of disassembly.
17. After installing, fill the differential carrier with gear oil up to the bottom of the filler plug hole. Refer to «DIFFERENTIAL GEAR OIL»(ref-325345-S00030987502009071800000) .

Inspect for oil leakage from the side oil seal.

If there is oil leakage, replace the oil seal.

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

1. Shift the select lever or gear shift lever to neutral.
2. Release the parking brake.
3. Loosen the wheel nuts.
4. Lift up the vehicle
5. Remove the wheels.
6. Remove the rear exhaust pipe and muffler. Non-turbo model Refer to «REMOVAL»(ref-325320-S35059142112009071800000) , Rear Exhaust Pipe. Refer to «REMOVAL»(ref-325320-S22382758332009071800000) , Muffler. Turbo model Refer to «REMOVAL»(ref-325336-S21151896522009071800000) , Rear Exhaust Pipe. Refer to «REMOVAL»(ref-325336-S04910540732009071800000) , Muffler.
7. Remove the DOJ of rear drive shaft from rear differential. Remove the ABS wheel speed sensor cable from the clamp. Disconnect the connector and remove the nut to remove the rear vehicle height sensor. (models with auto headlight beam leveler, left side only) Remove the bolts which secure the rear stabilizer link to the rear lateral link. Remove the bolts which secure the shock absorber to the rear lateral link. Remove the bolts which secure the rear lateral link to the housing. Remove the bolts which secure the trailing link to the housing. Remove the DOJ from the rear differential by using ST. NOTE: When removing the DOJ from the rear differential, fit the ST to the bolts as shown in the figure so as not to damage the side retainer. ST 28099PA100 DRIVE SHAFT REMOVER Suspend the rear drive shaft to the rear cross-member using wire. Remove the oil seal using ST. ST 398527700 PULLER ASSY Install a new side oil seal using the ST. NOTE: Apply differential gear oil to the oil seal lips. ST 398437700 DRIFT Insert the DOJ into rear differential. Attach the ST to rear differential. ST 28099PA090 OIL SEAL PROTECTOR Insert the spline shaft until the spline portion comes inside the side oil seal. Remove ST from rear differential. ST 28099PA090 OIL SEAL PROTECTOR Push the housing to insert DOJ completely into rear differential. Installing procedure hereafter is in the reverse order of removal. Inspect the wheel alignment and adjust if necessary. Re-initialize the auto headlight beam leveler system. (models with auto headlight beam leveler) Refer to «PROCEDURE»(ref-325323-S27547444052009071800000) , Auto Headlight Beam Leveler System.

1. Check the rear differential front member for damage, bend and corrosion. If damage, bend or corrosion is excessive, replace the rear differential front member.
2. Check the bushings of rear differential member for cracking, hardening and damage.

If cracking, hardening or damage is excessive, replace rear differential front member.

SYMPTOM REFERENCE