Differentials: Overhaul — Subaru Forester SJ (2012-2015)

DISASSEMBLY

To detect the real cause of trouble, inspect the following items before disassembling.

Tooth contact and backlash between hypoid driven gear and drive pinion
Hypoid driven gear runout on its back surface
Total preload of drive pinion

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Set the ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT SET
Remove the drain plug and filler plug.
Remove the air breather cap. NOTE: Do not attempt to remove the air breather cap unless necessary. Whenever the air breather cap is removed, replace it with a new part.
Remove the bolts, and then remove the rear cover.
Remove the side retainer attachment bolts, set the ST to differential case, and extract the side retainers RH and LH with a puller. NOTE: Side retainer shim of each side should be kept together with its mating retainer. Keep the side retainers separate by attaching tags or in similar ways to make it possible to identify RH and LH sides during reassembly. ST 398457700 ATTACHMENT
Remove the oil seal and O-ring from the side retainer.
Pull out the differential case assembly from the differential carrier. NOTE: Be careful not to hit the teeth of hypoid driven gear against the differential carrier.
When replacing the side bearing, remove the bearing race from the side retainer using ST. ST 398527700 PULLER ASSY
Using the ST, remove the bearing cone. NOTE: Do not attempt to disassemble the parts unless necessary. Set the ST so that its claws catch the edge of the bearing cone. Never mix up the RH and LH bearing races and cones. ST 18759AA000 PULLER ASSY
Remove the hypoid driven gear by loosening hypoid driven gear bolts.
Remove the pinion shaft lock pin from hypoid driven gear side using ST. ST 899904100 STRAIGHT PIN REMOVER
Draw out the pinion mate shaft, and remove pinion mate gears, pinion mate gear washers, side gears, and side gear thrust washers. NOTE: The gears and washers should be marked with RH or LH, front or rear, or kept separately.
Remove the self-locking nut while securing the companion flange with ST. ST 498427200 FLANGE WRENCH
Extract the companion flange with a puller.
Press the end of drive pinion shaft using ST and remove the rear bearing cone, preload adjusting spacer and washer. NOTE: Hold the drive pinion so as not to drop it. ST 398467700 DRIFT
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
Remove the front oil seal from differential carrier using ST. ST 398527700 PULLER ASSY
Remove the pilot bearing together with the front bearing cone and spacer using the ST. ST 398467700 DRIFT
When replacing the bearings, use a brass bar to tap out the front bearing race and rear bearing race in this order to remove them.

ASSEMBLY

Note. Assemble in the reverse order of disassembly. Check and adjust each part during assembly. Keep the shims and washers in order, so that they are not improperly installed. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply gear oil when installing the bearings and thrust washers. Be careful not to mix up the RH and LH bearing races. Use a new O-ring and gasket. Replace the oil seal with a new part at every disassembly. Be careful not to mix up the oil seal RH and LH. Apply differential gear oil to the lips when installing the oil seal.

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Scheme 50: ASSEMBLY

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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. Install the rear bearing race into the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 398477703 DRIFT 2 Install the front bearing race to the differential carrier using ST1 and ST2. NOTE: Use a new front bearing race. ST1 398477701 HANDLE ST2 398477702 DRIFT Insert ST1 into the differential carrier with the pinion height adjusting washer and rear bearing cone fitted onto it. NOTE: If tooth contact (drive pinion, hypoid driven gear) is normal in the inspection before disassembling, verify that the washer is not deformed, and then re-use the used washer. Install the pinion height adjusting washer, preload adjusting spacer and washer, front bearing cone, ST2, companion flange and self-locking nut. NOTE: Use new front bearing cone. ST1 398507702 DUMMY SHAFT ST2 398507703 DUMMY COLLAR 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: Use a new self-locking nut. Measure the preload in direction of tangent to the flange. Be careful not to give excessive preload. When tightening the self-locking nut, lock ST1 with ST2 as shown in the figure. ST1 398507702 DUMMY SHAFT ST2 398507704 BLOCK Tightening torque: 181.5 N.m (18.5 kgf-m, 133.9 ft-lb) Initial load: 18.1 - 38.8 N (1.8 - 4.0 kgf, 4.1 - 8.7 lbf) Initial torque: 0.69 - 1.47 N.m (0.07 - 0.15 kgf-m, 0.51 - 1.08 ft-lb) Preload adjusting washer Part No. Thickness 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) Preload adjusting spacer 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)
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. Attach the ST2. NOTE: At this time, install a provisionally selected or previously used pinion height adjusting washer. Measure and record the thickness. ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE ST3 398507703 DUMMY COLLAR 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 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed washer with this one. T = To + N - (H x 0.01) - 0.20 mm (0.0079 in) T Thickness of pinion height adjusting washer mm (in) To Thickness of washer temporarily inserted mm (in) N Clearance of thickness gauge mm (in) H Figure marked on drive pinion head Memo: (Example of calculation) To = 3.39 mm (0.1335 in) N = 0.24 mm (0.0094 in) H = + 1 T = 3.39 mm (0.1335 in) + 0.24 mm (0.0094 in) - 0.01 mm (0.0004 in) - 0.20 mm (0.0079 in) = 3.42 mm (0.1346 in) Result: Thickness = 3.42 mm (0.1346 in) Therefore use washer 383605200. (A) Pinion height adjusting washer 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)
Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST. ST 398177700 INSTALLER
Insert the drive pinion into the differential carrier, and install the preselected preload adjusting spacer and washer.
Press-fit the front bearing cone with ST1, ST2 and ST3. ST1 398507703 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER
Insert the spacer, then press-fit the pilot bearing with ST1 and ST2. NOTE: Use a new pilot bearing. ST1 399780104 WEIGHT ST2 899580100 INSTALLER
Using the ST, install the oil seal. NOTE: Use a new oil seal. Press-fit until the oil seal end comes 1 mm (0.04 in) inward from end of carrier. Apply differential gear oil to the oil seal lips. ST 498447120 INSTALLER
Press-fit the companion flange with ST1 and ST2. NOTE: Be careful not to damage the bearing. ST1 899874100 INSTALLER ST2 399780104 WEIGHT
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
Attach the new self-locking nut and use the ST to fix the companion flange in place, then tighten the self-locking nut. Tightening torque: 181.5 N.m (18.5 kgf-m, 133.9 ft-lb) ST 498427200 FLANGE WRENCH
Check the initial torque or initial load. Initial load: 18.1 - 38.8 N (1.8 - 4.0 kgf, 4.1 - 8.7 lbf) Initial torque: 0.69 - 1.47 N.m (0.07 - 0.15 kgf-m, 0.51 - 1.08 ft-lb)
Assembling differential case Install the side gears and pinion mate gears, with their side gear thrust washers, pinion mate gear washer, and pinion mate shaft, into the differential case. NOTE: Apply gear oil on both sides of the washer and on the pinion mate shaft before installing. Insert the pinion mate shaft into the differential case by aligning the pin holes. Measure the side gear backlash. Side gear backlash: 0.10 - 0.20 mm (0.004 - 0.008 in) Adjust the backlash as specified by selecting side gear thrust washer. Side gear thrust washer 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) Check the condition of rotation after applying oil to the gear tooth surfaces and washer surfaces. Drive the pinion shaft lock pin into the differential case. NOTE: Use a new pinion shaft lock pin. ST 899904100 STRAIGHT PIN REMOVER
Install the driven gear to the differential case. NOTE: Before installing bolts, apply seal material to bolt threads. Seal material: THREE BOND 1324 (Part No. 004403042) or equivalent Make sure there is no clearance between the differential case and driven gear. Tighten opposing bolts in order. Tightening torque: 103 N.m (10.5 kgf-m, 76.0 ft-lb)
Using the ST, press-fit the side bearing to the differential case. ST 398487700 DRIFT
Using the ST, press-fit the side bearing outer race to the side retainer. CAUTION: Make sure that the bearing outer races and cones are properly assembled. ST 398417700 DRIFT
Side retainer shim adjustment The hypoid driven gear backlash and side bearing preload can be adjusted by the side retainer shim thickness. 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. Install the side retainer shim. NOTE: Be careful not to mix up the side retainer shim RH and LH. Replace broken or corroded side retainer shims with a new part of the same thickness. Side 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) Align the arrow mark on the differential carrier with the arrow mark on the side retainer when installing the side retainer. NOTE: Be careful that the side bearing outer race is not damaged by the bearing roller. Tighten the side retainer bolts. Tightening torque: 10.5 N.m (1.1 kgf-m, 7.7 ft-lb) 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. If the backlash is outside the standard range, adjust the side retainer shim by the following method. When backlash is less than 0.1 mm (0.004 in): Reduce the thickness of shim on the back side of the hypoid driven gear and increase the thickness of shims on the teeth side of the hypoid driven gear. When backlash exceeds 0.2 mm (0.008 in): Increase the thickness of shim on the back side of the hypoid driven gear and reduce the thickness of shims on the teeth side of the hypoid driven gear. Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in) Measure the total preload of the drive pinion. If the total preload is outside the specification range, adjust the thickness of side retainer shims, increasing/reducing both shims by an even amount at a time. Total preload: 20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7 - 12.2 lbf)
Recheck the hypoid driven gear to drive pinion backlash. Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
Check pinion and hypoid driven gears rotate smoothly and make sure of the hypoid driven gear runout on its back surface. If the hypoid driven gear runout on its back surface exceeds the specification, check for any foreign objects between the hypoid driven gear and differential case, and for any deformation of the differential case or hypoid driven gear. Hypoid driven gear back surface runout: 0.05 mm (0.002 in)
Check and adjustment of the tooth contact of hypoid driven gear and drive pinion 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. 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. Correct tooth contact Check item: Tooth contact pattern is slightly shifted toward toe side under no-load rotation. (When driving, it moves towards the heel side.) Face contact Check item: Backlash is too large. Contact pattern Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side. Flank contact Check item: Backlash is too small. Contact pattern Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear. Toe contact (inside contact) Check item: Teeth contact area is too small. Contact pattern Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear. Heel contact (outside end contact) Check item: Teeth contact area is too small. Contact pattern Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.
If proper tooth contact is not obtained, readjust the drive pinion height by changing the RH and LH side retainer shims and the hypoid gear backlash. Drive pinion height ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE T = To + N - (H x 0.01) - 0.20 mm (0.0079 in) T Thickness of pinion height adjusting washer mm (in) To Thickness of washer temporarily inserted mm (in) N Clearance of thickness gauge mm (in) H Figure marked on drive pinion head Memo: Hypoid gear backlash Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
Remove the RH and LH side retainers.
Install the O-ring to left and right side retainers. NOTE: Use new O-rings.
Install the oil seal to the side retainers on both sides. < Ref. to «REPLACEMENT»(ref-662127-S42607418782014101300000) , Rear Differential Side Oil Seal. >
Align the arrow mark on the differential carrier with the arrow mark on the side retainer when installing the side retainer.
Apply liquid gasket to the bolts indicated by arrows, and tighten the bolts. Liquid gasket: THREE BOND 1110F, THREE BOND 1110B or equivalent Tightening torque: 10.5 N.m (1.1 kgf-m, 7.7 ft-lb)
Install the gasket and rear cover, and tighten the bolts to specified torque. NOTE: Use a new gasket. Tightening torque: 29.5 N.m (3.0 kgf-m, 21.8 ft-lb)
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.
Install the 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)
Install the filler plug. NOTE: After installing the rear differential assembly to the vehicle, fill the gear oil, then apply liquid gasket, and tighten to the specified torque. < Ref. to «REPLACEMENT»(ref-662127-S42594422432014101300000) , Differential Gear Oil. >

To detect the real cause of trouble, inspect the following items before disassembling.

Tooth contact and backlash between hypoid driven gear and drive pinion

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Set the ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT SET
Remove the drain plug and filler plug.
Remove the rear cover by removing retaining bolts. NOTE: Remove it by tapping with a plastic hammer.
Remove the air breather cap. NOTE: Do not attempt to remove the air breather cap unless necessary. Whenever the air breather cap is removed, replace it with a new part.
Remove the lock plate RH and LH.
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
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.
Remove the bearing race from side retainer RH and LH with ST1 and ST2. ST1 499705401 PULLER ASSY ST2 499705404 SEAT
Remove the oil seal from RH and LH side retainers. NOTE: Perform this operation only when changing oil seal.
Remove the O-ring.
Extract the bearing cone with ST1 and ST2. NOTE: Do not attempt to disassemble the parts unless necessary. Set the puller so that its claws catch the edge of the bearing cone. Store so that the right and left side bearing races and cones are not mixed together. ST1 899524100 PULLER SET ST2 399520105 SEAT
Using the ST, loosen the hypoid driven gear bolt and remove the hypoid driven gear. ST 18270KA020 SOCKET (E20)
Remove the spring pin from hypoid driven gear side using ST. ST 899904100 STRAIGHT PIN REMOVER
Draw out the pinion mate shaft and remove pinion mate gears, side gears and side gear thrust washers. NOTE: The gears and washers should be marked with RH or LH, front or rear, or kept separately.
Remove the self-locking nut while securing the companion flange with ST. ST 498427200 FLANGE WRENCH
Extract the companion flange with a puller.
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
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
Remove the front oil seal from differential carrier using ST. ST 398527700 PULLER ASSY
Remove the pilot bearing together with the front bearing cone and spacer using the ST. ST 398467700 DRIFT
When replacing the bearings, tap out the front bearing race and rear bearing race in this order using a brass bar to remove them.

Note. Assemble in the reverse order of disassembly. Check and adjust each part during assembly. Use new gaskets and O-rings. Keep the shims and washers in order, so that they are not improperly installed. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply gear oil when installing the bearings and thrust washers. Be careful not to mix up the RH and LH bearing races. Replace the oil seal and O-ring with a new part at every disassembly. Be careful not to mix up the side oil seal RH and LH. Apply differential gear oil to the lips when installing the oil seal.

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Scheme 100: ASSEMBLY

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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. Install the rear bearing race into the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 398477702 DRIFT Install the front bearing race to the differential carrier using ST1 and ST2. NOTE: Use a new front bearing race. ST1 398477701 HANDLE ST2 498447110 DRIFT Insert the front bearing cone. NOTE: Use new front bearing cone. 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. Insert the ST (DUMMY SHAFT) into case with the pinion height adjusting washer and rear bearing cone fitted onto it. Install the pinion height adjusting washer, preload adjusting spacer, washer, front bearing cone, spacer, pilot bearing, companion flange, and self-locking nut. NOTE: Use a new pilot bearing. ST 498447150 DUMMY SHAFT Part No. 32285AA000 Spacer 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: Use a new self-locking nut. Measure the preload in direction of tangent to the flange. Be careful not to give excessive preload. When tightening the self-locking nut, lock ST1 with ST2 as shown in the figure. ST1 498447150 DUMMY SHAFT ST2 398507704 BLOCK Tightening torque: 191 N.m (19.5 kgf-m, 140.9 ft-lb) Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lbf) Initial torque: 0.48 - 1.22 N.m (0.05 - 0.12 kgf-m, 0.35 - 0.90 ft-lb) Preload adjusting washer Part No. Thickness mm (in) 38336AA000 1.500 (0.0591) 38336AA120 1.513 (0.0596) 38336AA010 1.525 (0.0600) 38336AA130 1.538 (0.0606) 38336AA020 1.550 (0.0610) 38336AA140 1.563 (0.0615) 38336AA030 1.575 (0.0620) 38336AA150 1.588 (0.0625) 38336AA040 1.600 (0.0630) 38336AA160 1.613 (0.0635) 38336AA050 1.625 (0.0640) 38336AA170 1.638 (0.0645) 38336AA060 1.650 (0.0650) 38336AA180 1.663 (0.0655) 38336AA070 1.675 (0.0659) 38336AA190 1.688 (0.0665) 38336AA080 1.700 (0.0669) 38336AA200 1.713 (0.0674) 38336AA090 1.725 (0.0679) 38336AA210 1.738 (0.0684) 38336AA100 1.750 (0.0689) 38336AA220 1.763 (0.0694) 38336AA110 1.775 (0.0699) Preload adjusting spacer Part No. Length mm (in) 32288AA040 52.3 (2.059) 32288AA050 52.5 (2.067) 31454AA100 52.6 (2.071) 32288AA060 52.7 (2.075) 31454AA110 52.8 (2.079) 32288AA070 52.9 (2.083) 31454AA120 53.0 (2.087) 32288AA080 53.1 (2.091) 32288AA090 53.3 (2.098)
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. 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 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 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) T Thickness of pinion height adjusting washer mm (in) To Thickness of washer temporarily inserted mm (in) N Clearance of thickness gauge mm (in) Memo: (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. Pinion height adjusting washer Part No. Thickness mm (in) 32295AA200 0.150 (0.0059) 32295AA210 0.175 (0.0069) 32295AA220 0.200 (0.0079) 32295AA230 0.225 (0.0089) 32295AA240 0.250 (0.0098) 32295AA250 0.275 (0.0108)
Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST. ST 498175500 INSTALLER
Insert the drive pinion into the differential carrier, and install the preselected preload adjusting spacer and washer.
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
Insert the spacer, then press-fit the pilot bearing with ST1 and ST2. ST1 399780104 WEIGHT ST2 899580100 INSTALLER
Using the ST, install the oil seal. NOTE: Use a new oil seal. Press-fit until the oil seal end comes 1 mm (0.04 in) inward from end of carrier. Apply differential gear oil to the oil seal lips. ST 498447120 INSTALLER
Press-fit the companion flange with ST1 and ST2. NOTE: Be careful not to damage the pilot bearing. ST1 899874100 INSTALLER ST2 399780104 WEIGHT
Attach the self-locking nut and use the ST to fix the companion flange in place, then tighten the self-locking nut. NOTE: Use a new self-locking nut. Before installing the self-locking nut, apply the seal material to the threads of the drive pinion shaft and to the seating surface of the self-locking nut. 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
Check the initial torque or initial load. Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lbf) Initial torque: 0.48 - 1.22 N.m (0.05 - 0.12 kgf-m, 0.35 - 0.90 ft-lb)
Assembling differential case Install the side gears and pinion mate gears, with their side gear thrust washers and pinion mate shaft, into the differential case. NOTE: Apply gear oil on both sides of the washer and on the side gear shaft before installing. Insert the pinion mate shaft into the differential case by aligning the pin holes. The thrust washer inner surface has a chamfered side. Install the washer with the chamfered side facing toward the side gear. Measure the side gear backlash. Side gear backlash: 0.05 - 0.15 mm (0.002 - 0.006 in) Adjust the side gear backlash by selecting side gear thrust washer. Side gear thrust washer Part No. Thickness mm (in) 803135011 0.925 - 0.950 (0.0364 - 0.0374) 803135012 0.950 - 0.975 (0.0374 - 0.0384) 803135013 0.975 - 1.000 (0.0384 - 0.0394) 803135014 1.000 - 1.025 (0.0394 - 0.0404) 803135015 1.025 - 1.050 (0.0404 - 0.0413) Check the condition of rotation after applying oil to the gear tooth surfaces and washer surfaces. Drive the spring pin into the differential case. NOTE: Use new spring pin.
Install the hypoid driven gear to differential case. NOTE: Before installing bolts, apply seal material to bolt threads. Seal material: THREE BOND 1324 (Part No. 004403042) or equivalent Tighten opposing bolts in order. 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) While checking the tightening angle with the angle gauge, further tighten the hypoid driven gear mounting bolts. Tightening angle: 35°±2°
Using the ST, press-fit the side bearing to the differential case. ST 498485400 DRIFT
Assemble the side retainer. 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. Apply differential gear oil to the oil seal lip. ST 498447100 INSTALLER 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 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. Temporally tighten the side retainers RH and LH in differential carrier to install.
Perform the backlash adjustment between the hypoid driven gear and drive pinion, and preload adjustment of differential side bearing. Turn the drive pinion with ST for better fitting of differential side bearing. ST 498427200 FLANGE WRENCH Using the ST, tighten side retainer RH, and then tighten side retainer LH until there is no backlash. ST 18630AA010 WRENCH COMPL RETAINER 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 (approx. 1 and 1/2 teeth) + approx. 1/2 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. Temporarily tighten the lock plate. NOTE: Turn over the lock plate to shift the holder by 1/2 teeth. 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)
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. NOTE: Use new O-rings.
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)
Recheck the backlash between hypoid driven gear and drive pinion. Backlash: 0.10 - 0.15 mm (0.004 - 0.006 in)
Checking and adjusting the tooth contact of hypoid driven gear 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. 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. Correct tooth contact Check item: Tooth contact pattern is slightly shifted toward toe side under no-load rotation. (When driving, it moves towards the heel side.) Face contact Check item: Backlash is too large. Contact pattern Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side. Flank contact Check item: Backlash is too small. Contact pattern Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear. Toe contact (inside contact) Check item: Teeth contact area is too small. Contact pattern Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear side. Heel contact (outside end contact) Check item: Teeth contact area is too small. Contact pattern Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.
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.
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)
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.
Install the drain plug. NOTE: Use a new gasket. Tightening torque: 50 N.m (5.1 kg-m, 36.9 ft-lb)
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 «REPLACEMENT»(ref-662127-S42594422432014101300000) , Differential Gear Oil. >

Differentials: Overhaul Subaru Forester SJ