Differential: Overhaul Subaru Impreza GC/GF

Disassembly

1. Mark front and rear drive shaft for reassembly reference. Remove bolts attaching front and rear drive shaft. Install companion flange in a soft-jawed vise. Remove self locking nut and washer.
2. Mark companion flange and rear drive shaft for reassembly reference. Use appropriate press to remove companion flange from rear drive shaft. Using a soft-faced hammer, drive rear drive shaft from center bearing. DO NOT damage shaft threads.

Reassembly

Mount center bearing onto drive shaft. Apply grease to both sides of washer and attach washer to center bearing end face. With reference marks aligned, install companion flange onto rear drive shaft. Install washer and new self locking nut.

1. Mark right and left side bearing nut (axle shaft holder) for reassembly reference. Remove lock plates. Using appropriate wrench, remove axle shaft holders. Remove differential case assembly from carrier.
2. Remove side bearing races from axle shaft holder with puller. Remove side bearings from carrier housing. Remove ring gear. Unstake pinion shaft lock pin. Drive pin out from flange side. Remove pinion shaft, pinion gears, side gears and thrust washers. (Схема №1)
3. Maintain thrust washers, pinion gears and side gears in order for reassembly reference. Remove drive pinion nut. Remove pinion flange with puller. Press drive pinion from carrier housing with rear bearing inner race, bearing spacer and adjusting washer.
4. Remove companion flange oil seal. Using brass drift, remove pilot bearing. (Схема №1) Remove front bearing. Drive out front bearing race.

1. Remove rear cover. Mark right and left side bearing retainers for reassembly reference. Remove side bearing retaining bolts. Using a puller, remove side bearing retainers. Remove differential case assembly from carrier. Avoid hitting teeth against case.
2. Remove side bearing races from side nuts with puller. Using puller, remove side bearings if replacement necessary. Unstake pinion shaft lock pin. Drive pin out from flange side. Remove pinion shaft, pinion gears, side gears and thrust washers. (Схема №1)
3. Maintain thrust washers, pinion gears and side gears in order for reassembly reference. Remove drive pinion nut. Remove pinion flange with puller. Press drive pinion from carrier housing with rear bearing inner race, bearing spacer and adjusting washer.
4. Remove companion flange oil seal. Using brass drift, remove pilot bearing. (Схема №1) Remove front bearing. Drive out front bearing race.