Differentials: Other Subaru Forester SJ

REAR DIFFERENTIAL

When replacing a rear differential assembly, select the correct one according to the following table.

Note. Using a different rear differential assembly will cause he drive train and tires to drag or emit abnormal noise. For option code, refer to "ID" section. < Ref. to IDENTIFICATION , Identification. >

REAR DIFFERENTIAL GEAR OIL

Recommended gear oil

GL-5 (75W-90) or equivalent

Scheme 170

SERVICE DATA

Scheme 171

Tightening torque: N.m (kgf-m, ft-lb)

T1: 10.5 (1.1, 7.7)

T2: 29.5 (3.0, 21.8)

T3: 49 (5.0, 36.1)

T4: 103 (10.5, 76.0)

T5: 181.5 (18.5, 133.9)

Scheme 172

Tightening torque: N.m (kgf-m, ft-lb)

T1: 25 (2.5, 18.4)

T2: 50 (5.1, 36.9)

T3: < Ref. to ASSEMBLY , Rear Differential (VA-type). >

T4: 191 (19.5, 140.9)

Scheme 173

Tightening torque: N.m (kgf-m, ft-lb)

T1: 50 (5.1, 36.9)

T2: 70 (7.1, 51.6)

T3: 110 (11.2, 81.1)

CAUTION

1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
5. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
6. Use SUBARU genuine gear oil, grease or equivalent. Do not mix gear oil, grease, etc. of different grades or manufacturers.
7. Be sure to tighten fasteners including bolts and nuts to the specified torque.
8. Place shop jacks or rigid racks at the specified points.
9. Apply gear oil onto sliding or revolving surfaces before installation.
10. Before installing the O-ring or snap ring, apply a 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 cloth between the part and the vise.
12. Avoid damaging the mating surface of the case.

GENERAL TOOL

Scheme 174

Scheme 175

1. Lift up the vehicle.
2. Remove the filler plug, and then check the gear oil. Replace the gear oil if it is contaminated, deteriorated or cloudy. < Ref. to «REPLACEMENT»(ref-662127-S42594422432014101300000) , Differential Gear Oil. >
3. Check that the gear oil level is within -5 mm (-0.2 in) from the bottom of the filler plug hole. If the level is low, make sure that there is no oil leakage and refill up to the bottom of filler plug hole. NOTE: On VA1-types at factory settings, the oil level may be within -14 mm (-0.6 in) from the bottom of the filler plug. This is at normal level, requiring no oil refill. T-type VA1-type
4. Install the filler plug. NOTE: For the T-type, apply liquid gasket to the filler plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent For VA type, use a new gasket. Tightening torque: T-type: 49 N.m (5.0 kgf-m, 36.1 ft-lb) VA-type: 50 N.m (5.1 kgf-m, 36.9 ft-lb)

CVT (TR580) MODEL

For front differential for the CVT (TR580) model, refer to the "CVT (TR580)" section. < Ref. to FRONT DIFFERENTIAL ASSEMBLY . >

CVT (TR690) MODEL

For front differential for the CVT (TR690) model, refer to the "CVT (TR690)" section. < Ref. to FRONT DIFFERENTIAL ASSEMBLY . >

MT MODEL

For the front differential of the manual transmission model, refer to "6MT" section. < Ref. to FRONT DIFFERENTIAL ASSEMBLY . >

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Scheme 185

1. Shift the select lever or gear shift lever to neutral.
2. Disconnect the ground cable from battery.
3. Release the parking brake.
4. Loosen the wheel nuts.
5. Lift up the vehicle.
6. Remove the rear wheels.
7. Drain differential gear oil. < Ref. to «REPLACEMENT»(ref-662127-S42594422432014101300000) , Differential Gear Oil. >
8. Remove the rear exhaust pipe. 2.5 L non-turbo model < Ref. to «REMOVAL»(ref-662139-S39836269742014101300000) , Rear Exhaust Pipe. > 2.0 L turbo model < Ref. to «REMOVAL»(ref-662147-S19685566712014101300000) , Rear Exhaust Pipe. >
9. Remove the heat shield cover.
10. Remove the propeller shaft. < Ref. to «REMOVAL»(ref-662131-S39075214892014101300000) , Propeller Shaft. >
11. Loosen the self-lock nuts which hold the rear differential to the rear sub frame assembly.
12. Remove the DOJ of rear drive shaft from rear differential using ST or tire lever. NOTE: For the T-type, use the ST. For the VA-type, use the tire lever. When removing the DOJ from the rear differential, fit the tire lever or ST to the bolts as shown in the figure so as not to damage the side retainer. T-type ST 28099PA100 DRIVE SHAFT REMOVER VA-type
13. Set the rear differential to transmission jack.
14. Remove the rear differential front member.
15. Remove the self-lock nuts which hold the rear differential to the rear sub frame assembly.
16. Pull out the rear differential stud bolt from rear differential mount bushing. NOTE: When removing the stud bolt from the rear differential mount bushing, carefully adjust the angle and location of transmission jack and jack stand, if necessary.
17. Lower the transmission jack.
18. Pull out the rear drive shaft from the rear differential. NOTE: If it is difficult to pull out the rear drive shaft from rear differential, use the ST for T-type and the tire lever for VA-type. ST 28099PA100 DRIVE SHAFT REMOVER
19. Lower the transmission jack.
20. Secure the rear drive shaft to rear lateral link using wire.
21. Remove the rear differential member plate from rear differential.

Scheme 186

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1. Attach the rear differential member plate to the rear differential.
2. Set the rear differential to transmission jack.
3. Set the ST to the rear differential. ST 28099PA090 OIL SEAL PROTECTOR
4. Insert the rear drive shaft until the spline portion of the rear drive shaft exceeds the side oil seal.
5. Remove ST from rear differential.
6. Push the rear differential from side to side to insert the DOJ into rear differential completely.
7. Adjust the transmission jack, if necessary, and insert the rear differential stud bolt into the rear differential mount bushing properly.
8. After inserting the rear differential stud bolt into the rear differential mount bushing, lift up the transmission jack and align the rear differential to its attachment position.
9. Tighten a new self-locking nut temporarily to the rear differential stud bolt.
10. Install the rear differential front member, and temporarily attach and tighten a new self-locking nut.
11. Remove the transmission jack.
12. Tighten the 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)
13. Tighten the self-locking nut. Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
14. Install the propeller shaft. < Ref. to «INSTALLATION»(ref-662131-S04185762852014101300000) , Propeller Shaft. >
15. Install the heat shield cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
16. Install the rear exhaust pipe. 2.5 L non-turbo model < Ref. to «INSTALLATION»(ref-662139-S15644690322014101300000) , Rear Exhaust Pipe. > 2.0 L turbo model < Ref. to «INSTALLATION»(ref-662147-S39002575412014101300000) , Rear Exhaust Pipe. >
17. Fill differential gear oil. < Ref. to «REPLACEMENT»(ref-662127-S42594422432014101300000) , Differential Gear Oil. >
18. Installing procedure hereafter is in the reverse order of removal.
19. Perform " «REAR DIFFERENTIAL INSPECTION MODE»(ref-662127-S24575892702014101300000) " using the Subaru Select Monitor. (CVT model) < Ref. to «REAR DIFFERENTIAL INSPECTION MODE»(ref-662127-S24575892702014101300000) . > CAUTION: Be sure to perform rear differential inspection mode when the following work has been performed. Replacement of rear differential Replacement of rear differential hypoid gear set Replacement of transmission assembly Replacement of front differential hypoid gear set

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.

Scheme 193

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.

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.

TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION

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

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.

Scheme 194

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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)
3. Set the gauge inside of the companion flange, and measure the runout. Limit of runout: 0.08 mm (0.003 in)
4. 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.
5. If the runout exceeds the limit 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.

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

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

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

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

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

Side gear backlash

0.05 - 0.15 mm (0.002 - 0.006 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.

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.

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)
3. Set the gauge inside of the companion flange, and measure the runout. Limit of runout: 0.08 mm (0.003 in)
4. 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.
5. If the runout exceeds the limit 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.

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

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

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

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

PROCEDURE

1. Shift the select lever to "P" range.
2. Apply the parking brake.
3. Lift up the vehicle. WARNING: Lift up the vehicle until the tire bottom is 30 cm or more above the ground.
4. Connect the Subaru Select Monitor to data link connector.
5. Turn the ignition switch to ON. (For model with push button start, press the push button ignition switch twice without depressing brake pedal.)
6. Select {Work Support} in the «Transmission Diagnosis» screen of Subaru Select Monitor.
7. Select {Maintenance mode} in the «Work Support» screen of Subaru Select Monitor.
8. Select {Rear differential inspection mode} in the «Maintenance mode» screen of the Subaru Select Monitor.
9. Follow the messages displayed on the Subaru Select Monitor screen when working.
10. The results of the rear differential inspection mode are displayed on the Subaru Select Monitor screen. When ended normally: "The rear differential has been replaced normally." When ended abnormally: "A rear differential abnormality has been detected. Reinspect the items at the time of rear differential installation." When interrupted: "Inspection is stopped. Restart this inspection mode from the beginning."
11. After the message "Inspection has been completed. Set the ignition switch to OFF." appears, the rear differential inspection mode completes. NOTE: When the rear differential inspection mode is completed properly, the following warning lights may illuminate. But this is not a malfunction. If warning light illuminates, clear the memory. VDC/ABS, engine, power steering, EyeSight For detailed operation procedures, refer to "PC application help for Subaru Select Monitor". If the rear differential inspection mode does not end normally, repeat the mode until it ends normally. When the inspection mode does not end normally, the AWD warning light will start blinking at 2 Hz. When the rear differential inspection mode ends abnormally, the front differential and rear differential may be different from the specifications for the vehicle. When the rear differential inspection mode is interrupted, the following reasons are possible. Message Main reasons for abnormal termination "Inspection is stopped." "Inspection is stopped. Restart this inspection mode from the beginning." TCM has detected a failure. VDC has a failure. Brake is applied after start during automatic running. Too delayed operation to the instructions displayed on the Subaru Select Monitor. "TCM incompatible. Rear differential inspection mode is stopped." The model does not support the rear differential inspection mode. The TCM has detected a fault. Inspect following the manual. TCM has detected a failure.
12. Perform "Function Check Sequence" for VDC. < Ref. to «READ FREEZE FRAME DATA»(ref-662151-S34216119672014101300000) , OPERATION, Subaru Select Monitor. > < Ref. to «ADJUSTMENT»(ref-662135-S18423196602014101300000) , VDC Control Module and Hydraulic Control Unit (VDCCM&H/U). >