Differentials: Diagnosis Subaru Outback BP

INSPECTION

Wash all the disassembled parts clean, and examine them for wear, damage, or other defects. Repair or replace defective parts as necessary.

1. Crown gear and drive pinion. If abnormal tooth contact is evident, find out the cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment. If crack, score, or seizure is evident, replace as a set. Slight damage of tooth can be corrected by oil stone or the like.
2. Side gear and pinion mate gear Replace if crack, score, or other defects are evident on tooth surface. Replace if thrust washer contacting surface is worn or seized. Slight damage of the surface can be corrected by oil stone or the like.
3. Bering Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident.
4. Thrust washers of side gear and pinion mate gear Replace if seizure, flaw, abnormal wear or other defect is evident.
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 worn or cracked.
8. Companion flange Replace if the oil seal lip contacting surfaces have flaws.

Wash all the disassembled parts clean, and example them for wear, damage, or other defects. Repair or replace defective parts as necessary.

1. Crown gear and drive pinion If abnormal tooth contact is evident, find out the cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment. If crack, score, or seizure is evident, replace as a set. Slight damage of tooth can be corrected by oil stone or the like.
2. Side gear and pinion mate gear Replace if crack, score, or other defects are evident on tooth surface. Replace if thrust washer contacting surface is worn or seized. Slight damage of the surface can be corrected by oil stone or the like.
3. Bearing Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident.
4. Thrust washers of side gear and pinion mate gear Replace if seizure, flaw, abnormal wear or other defect is evident.
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 worn or cracked.
8. Companion flange Replace if the oil seal lip contacting surfaces have flaws.

Check front oil seal portion for oil leakage, if any leak is found, replace the oil seal and inspect propeller shaft.

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Disconnect ground cable from battery.
2. Move select lever or gear shift lever to "N".
3. Release the parking brake.
4. Remove oil drain plug, and drain gear oil. Install oil drain plug. NOTE: Apply fluid gasket to oil drain plug for T-type. VA-type uses a new aluminum gasket. Fluid packing: THREE BOND 1105 (Part No.:0044030 or equivalent Tightening torque: T-type; 49 N.m (5.0 kgf-m, 36.2 ft-lb) VA-type; 34 N.m (3.5 kgf-m, 25.3 ft-lb)
5. Jack-up rear wheels and support the vehicle body with sturdy racks.
6. Remove rear exhaust pipe and muffler.
7. Remove propeller shaft from body. .
8. Remove self-locking nut while holding companion flange with ST. ST 498427200 FLANGE WRENCH
9. Remove protector nuts.
10. Extract companion flange using ST. ST 399703600 PULLER ASSY
11. Remove oil seal using ST. ST 398527700 PULLER ASSY
12. Fit a new oil seal using ST. ST 498447120 OIL SEAL INSTALLER
13. Install companion flange. NOTE: Use a plastic hammer to install companion flange.
14. Tighten new 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: T-type 181 N.m (18.5 kgf-m, 134 ft-lb) VA-type 191 N.m (19.5 kgf-m, 141 ft-lb)
15. Reassembling procedure hereafter is the reverse of the disassembling.

Scheme 12

1. Disconnect ground cable from battery.
2. Jack-up the vehicle.
3. Using a transmission jack, support rear differential, and remove rear differential front member.

Scheme 13

1. Install rear differential front member. Tightening torque: T1: 65 N.m (6.6 kgf-m, 48 ft-lb) T2: 110 N.m (11.2 kgf-m, 81 ft-lb)

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

Scheme 14