Differentials: Other Subaru Outback BP

SERVICE DATA

Service Data

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1. VA-type
2. T-type

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CAUTION

1. Wear working clothing, including a cap, protected goggles, and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust or dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
5. Be careful not to burn your hands, because each part on the vehicle is hot after running.
6. Use SUBARU genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with that of another grade or from other manufacturers.
7. Be sure to tighten fasteners including bolts and nuts to the specified torque.
8. Place shop jacks or safety stands at the specified points.
9. Apply gear oil onto sliding or revolution surfaces before installation.
10. Before installing O-rings or snap rings, apply 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 shop cloth between the part and the vise.
12. Avoid damaging the mating face of the case.

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1. Take out filler plug, and replace gear oil if it is contaminated or deteriorated. Refer to «REPLACEMENT»(ref-208405-S04406215812005120700000) .
2. Check gear oil level is up to the bottom part of filler bolt. If the level is low, refill up to the bottom of filler bolt.

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1. Disconnect ground cable from battery.
2. Jack-up vehicle and support it with sturdy racks
3. Remove the oil drain plug and filler plug, and drain the gear oil. CAUTION: Be careful not to burn your hands, because gear oil becomes extremely hot after running.
4. Tighten oil drain plug. NOTE: Apply fluid gasket to drain plug for T-type. VA-type uses a new aluminum gasket. Fluid gasket: THREE BOND 1105 (Part No.: 004403010) or equivalent Tightening torque: T-type; 49.0 N.m (5.0 kgf-m, 36.2 ft-lb) VA-type; 34 N.m (3.5 kgf-m, 25.3 ft-lb)
5. Fill differential carrier with gear oil to the upper plug level. CAUTION: Carefully refill gear oil while watching the level. Excess or insufficient oil must be avoided. Oil capacity: 0.8 (0.8 US qt, 0.7 Imp qt)
6. Install filler plug. NOTE: Apply fluid gasket to filler plug for T-type. VA-type uses a new aluminum gasket. Fluid gasket: THREE BOND 1105 (Part No.: 004403010) or equivalent Tightening torque: T-type; 49.0 N.m (5.0 kgf-m, 36.2 ft-lb) VA-type; 34 N.m (3.5 kgf-m, 25.3 ft-lb)

AT MODEL

For front differential of automatic transmission, refer to FRONT DIFFERENTIAL .

MT MODEL

For front differential of manual transmission, refer to FRONT DIFFERENTIAL ASSEMBLY .

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1. Disconnect ground cable from battery.
2. Move select lever or gear shift lever to "N".
3. Loosen wheel nuts.
4. Release the parking brake.
5. Jack-up vehicle and support it with sturdy racks.
6. Remove wheels.
7. Remove rear exhaust pipe and muffler.
8. Remove heat shield cover.
9. Remove propeller shaft. .
10. Remove rear differential protector (if equipped).
11. Prepare a transmission jack and a band.
12. Loosen self-locking nuts connecting rear differential to rear crossmember.
13. Remove DOJ of rear drive shaft from rear differential using ST. ST 28099PA100 DRIVE SHAFT REMOVER
14. Remove protector nuts.
15. Remove rear differential front member.
16. Support rear differential with transmission jack.
17. Be sure to secure differential to transmission jack by hand.
18. Remove self-locking nuts connecting rear differential to crossmember.
19. Remove rear differential stud bolt from rear crossmember bushing. NOTE: Carefully adjust angle and position of transmission jack and jack stand as required during stud bolt removal.
20. After removing rear differential stud bolt from rear crossmember, lower transmission jack stand. Do not allow rear drive shaft to strike lateral link bolt.
21. Pull out axle shaft from rear differential. NOTE: If axle shaft is difficult to remove from rear differential, use ST to remove it. ST 28099PA100 DRIVE SHAFT REMOVER
22. Take down transmission jack.
23. Secure rear drive shaft to lateral link use wire.
24. Remove protector and rear differential member plate from rear differential.

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1. Install protector and rear differential member plate to rear differential.
2. Set rear differential to transmission jack. NOTE: Secure rear differential to transmission jack using a band.
3. Install ST to rear differential. ST 28099PA090 OIL SEAL PROTECTOR
4. Insert the spline shaft until the spline portion is inside the side oil seal.
5. Remove ST from rear differential. ST 28099PA090 OIL SEAL PROTECTOR Completely insert axle shaft into rear differential by pressing rear differential.
6. Adjust transmission jack as required so rear differential stud bolt is properly inserted into rear crossmember bushing.
7. After rear differential stud bolt has been inserted into rear crossmember bushing, raise transmission jack to make jack rear differential level.
8. Temporarily tighten rear crossmember self-locking nuts.
9. Remove band from rear differential. Raise rear differential just enough to move transmission jack away from it.
10. 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)
11. Tighten self-locking nuts. Tightening torque: 70 N.m (7.1 kgf-m, 51 ft-lb)
12. Tighten protector nut. Tightening torque: 65 N.m (6.6 kgf-m, 48.0 ft-lb)
13. Take down transmission jack.
14. Install propeller shaft.
15. Install heat shield cover.
16. Install rear exhaust pipe and muffler.
17. After installing rear differential carrier on vehicle, remove filler plug and replenish gear oil up to upper level mark. Oil capacity: 0.8 (0.8 US qt, 0.7 Imp qt)
18. Tighten filler plug. NOTE: Apply fluid gasket to plug. Fluid gasket: THREE BOND 1105 (Part No. 04403010) or equivalent Tightening torque: 49.0 N.m (5.0 kgf-m, 36.2 ft-lb)

SIDE GEAR BACKLASH

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

1. Side gear backlash: 0.1 - 0.2 mm (0.004 - 0.008 in)

If side gear backlash is not within the specification, adjust clearance as specified by selecting side gear thrust washer.

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CROWN GEAR BACKLASH

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

1. Crown gear backlash: 0.1 - 0.2 mm (0.004 - 0.008 in)

If crown gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.

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CROWN GEAR RUNOUT

Using a dial gauge, check the crown gear runout.

1. Crown gear runout: Less than 0.05 mm (0.0020 in)

If the crown gear runout exceeds 0.05 mm (0.0020 in), replace the crown gear.

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TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION

Inspect tooth contact between crown gear and driven pinion. Refer to ASSEMBLY .

TOTAL PRELOAD

Using a gauge, check the turning resistance increase.

1. Turning resistance increase: 2.9 - 10.8 N (0.3 - 1.1 kgf, 0.7 - 2.4 lb)

If the increase of the resistance is not within the specification, adjust the side bearing retainer shims.

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Adjust side gear backlash. Refer to ASSEMBLY .

Adjust crown gear backlash. Refer to ASSEMBLY .

Adjust the tooth contact between crown gear and drive pinion gear.

Refer to ASSEMBLY .

Adjust side bearing shim.

Refer to ASSEMBLY .

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1. Disconnect ground cable from battery.
2. Move select lever or gear shift lever to "N".
3. Loosen wheel nuts.
4. Release the parking brake.
5. Jack-up vehicle and support it with sturdy racks.
6. Remove wheels.
7. Remove rear exhaust pipe and muffler.
8. Remove heat shield cover.
9. Remove propeller shaft. .
10. Prepare a transmission jack and a band.
11. Loosen self-locking nuts connecting rear differential to rear crossmember.
12. Remove DOJ of rear drive shaft from rear differential.
13. Remove protector nuts.
14. Remove nuts which secure rear differential front member.
15. Support rear differential with transmission jack.
16. Remove rear differential front member.
17. Fix rear differential at band.
18. Remove self-locking nuts connecting rear differential to rear crossmember.
19. Remove rear differential stud bolt from rear crossmember bushing. NOTE: Carefully adjust angle and position of transmission jack and jack stand as required during stud bolt removal.
20. After removing rear differential stud bolt from rear crossmember, lower transmission jack stand. Do not allow rear drive shaft to strike lateral link bolt.
21. Pull out axle shaft from rear differential. NOTE: If axle shaft is difficult to remove from rear differential, use a tire lever to remove it.
22. Take down transmission jack.
23. Secure rear drive shaft to lateral link using wire.
24. Remove protector and rear differential member plate from rear differential.

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1. Insert protector and plate to rear differential.
2. Set rear differential to transmission jack. NOTE: Secure rear differential to transmission jack using a band.
3. Install ST to rear differential. ST 28099PA090 OIL SEAL PROTECTOR
4. Insert the spline shaft until the spline portion is inside the side oil seal.
5. Remove ST from rear differential. ST 28099PA090 OIL SEAL PROTECTOR
6. Completely insert axle shaft into rear differential by pressing rear differential.
7. Adjust transmission jack as required so rear differential stud bolt is properly inserted into rear crossmember bushing.
8. After rear differential stud bolt has been inserted into rear crossmember bushing, raise transmission jack to make jack rear differential level.
9. Temporarily tighten rear crossmember self-locking nuts.
10. Remove band from rear differential. Raise re differential just enough to move transmission jack away from it.
11. 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)
12. Tighten self-locking nuts. Tightening torque: 70 N.m (7.1 kgf-m, 51 ft-lb)
13. Tighten protector nut. Tightening torque: 65 N.m (6.6 kgf-m, 48.0 ft-lb)
14. Take down transmission jack.
15. Install propeller shaft. .
16. Install heat shield cover.
17. Install rear exhaust pipe and muffler.

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

1. Side gear backlash: 0.05 - 0.15 mm (0.0020 - 0.0059 in)

If side gear backlash is not within the specification, adjust clearance as specified by selecting side gear trust washer.

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

1. Crown gear backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)

If crown gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.

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Inspect tooth contact between crown gear and drive pinion.

Refer to ASSEMBLY .

Adjust side gear backlash.

Refer to ASSEMBLY .

Adjust crown gear backlash.

Refer to ASSEMBLY .

Adjust the tooth contact between crown gear and drive pinion gear.

Refer to ASSEMBLY .