Differential System: Other Subaru Outback BR

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 the drive train and tires to drag or emit abnormal noise.

SPECIFICATION CHART

REAR DIFFERENTIAL GEAR OIL

Recommended gear oil: GL-5(75W-90)

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SERVICE DATA

SERVICE DATA

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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

GENERAL TOOL DESCRIPTION

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1. Remove the oil filler plug, and then check the gear oil. Replace the gear oil if it is contaminated or deteriorated. Ref. to «REPLACEMENT»(ref-371904-S29820045652010091900000) , Differential Gear Oil.
2. Check that the gear oil level is within -5 mm (-0.2 in) from the bottom of the oil filler plug hole. If the level is low, make sure that there is no oil leakage and refill up to the bottom of oil 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 oil filler plug. This is at normal level, requiring no oil refill. T-type VA1-type VA2-type

CVT MODEL

For front differential for the CVT model, refer to the "CVT" article. Ref. to FRONT DIFFERENTIAL ASSEMBLY .

AT MODEL

For front differential of 5AT model, refer to "5AT article. Ref. to FRONT DIFFERENTIAL ASSEMBLY .

MT MODEL

For front differential for the 6MT model, refer to the "6MT" article. Ref. to FRONT DIFFERENTIAL ASSEMBLY .

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1. Set the vehicle on a lift.
2. Shift the select lever or gear shift lever to neutral.
3. Release the parking brake.
4. Disconnect the ground cable from battery.
5. Loosen the wheel nuts.
6. Lift up the vehicle.
7. Remove the rear wheels.
8. Drain differential gear oil. Ref. to «REPLACEMENT»(ref-371904-S29820045652010091900000) , Differential Gear Oil.
9. Remove the rear exhaust pipe. 2.5 L SOHC model Ref. to «REMOVAL»(ref-371916-S24336289852010091900000) , Rear Exhaust Pipe. 2.5 L DOHC turbo model Ref. to «REMOVAL»(ref-371921-S14593980742010091900000) , Rear Exhaust Pipe. 3.6 L model Ref. to «REMOVAL»(ref-371938-S08736757402010091900000) , Rear Exhaust Pipe.
10. Remove the heat shield cover.
11. Remove the propeller shaft. Ref. to «REMOVAL»(ref-371909-S33653701722010091900000) , Propeller Shaft.
12. Loosen the self-lock nuts which hold the rear differential to rear crossmember.
13. 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. T-type ST 28099PA100 DRIVE SHAFT REMOVER VA-type When removing the DOJ from the rear differential, place the tire lever against the bolt as shown in the figure so as not to damage the side retainer.
14. Set the rear differential to transmission jack.
15. Remove the mass damper. (CVT model)
16. Remove the rear differential front member.
17. Remove the self-locking nuts which hold the rear differential to the crossmember.
18. Remove the rear differential stud bolt from rear crossmember bushing. NOTE: When removing the stud bolt from the rear crossmember bushing, carefully adjust the angle and location of transmission jack and jack stand, if necessary.
19. Lower the transmission jack.
20. Pull out the axle shaft from rear differential. NOTE: If it is difficult to remove the axle shaft from rear differential, use the ST for T-type and the tire lever for VA-type. ST 28099PA100 DRIVE SHAFT REMOVER If a circlip is attached to the removed axle shaft for VA2 type, remove the differential case assembly and replace it with a new part.
21. Lower the transmission jack.
22. Secure the rear drive shaft to rear lateral link using wire.
23. Remove the rear differential member plate from rear differential.

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1. Install 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 axle 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 rear axle shaft into rear differential completely.
7. Adjust the transmission jack, if necessary, and insert the rear differential stud bolt into rear crossmember bushing properly.
8. After inserting the rear differential stud bolt into the rear crossmember bushing, lift up the transmission jack and align the rear differential to its attachment position.
9. Tighten a new self-locking nut temporarily to rear crossmember.
10. Install the rear differential front member with a new 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)
11. Install the mass damper with a new self-locking nut. (CVT model) Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
12. Tighten the self-locking nut. NOTE: For models other than OUTBACK model, tighten the self-locking nut using the ST. ST 41399YC000 SOCKET WRENCH (17) Tightening torque: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
13. Remove the transmission jack.
14. Install the propeller shaft. Ref. to «INSTALLATION»(ref-371909-S25688249532010091900000) , 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 SOHC model Ref. to «INSTALLATION»(ref-371916-S31662490962010091900000) , Rear Exhaust Pipe. 2.5 L DOHC turbo model Ref. to «INSTALLATION»(ref-371921-S14454219392010091900000) , Rear Exhaust Pipe. 3.6 L model Ref. to «INSTALLATION»(ref-371938-S01176927902010091900000) , Rear Exhaust Pipe.
17. Fill differential gear oil. Ref. to «REPLACEMENT»(ref-371904-S29820045652010091900000) , Differential Gear Oil.
18. Hereafter, install in the reverse order of removal.
19. Perform "Rear Differential Inspection Mode" using the Subaru Select Monitor. (CVT model) Ref. to «REAR DIFFERENTIAL INSPECTION MODE»(ref-371904-S05120778062010091900000) . 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.

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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 not within the specification, adjust the side bearing preload or 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 exceeds 0.05 mm (0.002 in), 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.

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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 even 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).

VA1-TYPE

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

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

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1. Set the ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT SET
2. Remove the oil drain plug and oil filler plug.
3. Remove the rear cover by removing retaining bolts. NOTE: Remove it by tapping with a plastic hammer.
4. Remove the air breather cap. NOTE: Do not attempt to replace the air breather cap unless necessary. Whenever the air breather cap is removed, replace it with a new part.
5. Remove the lock plate RH and LH.
6. 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
7. Pull out the differential case assembly from differential carrier. NOTE: Be careful not to hit the teeth of hypoid driven gear against the case.
8. Remove the bearing race from side retainer RH and LH with ST1 and ST2. ST1 499705401 PULLER ASSY ST2 499705404 SEAT
9. Remove the oil seal from the RH and LH side retainers using a screwdriver. NOTE: Perform this operation only when changing oil seal.
10. 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
11. Remove the hypoid driven gear by loosening hypoid driven gear bolts.
12. Remove the spring pin from hypoid driven gear side using ST. ST 899904100 STRAIGHT PIN REMOVER
13. Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers. NOTE: The gears should be marked or kept separated right and left, and front and rear as well as thrust washers.
14. Remove the self-locking nut while holding the companion flange with ST. ST 498427200 FLANGE WRENCH
15. Extract the companion flange with a puller.
16. 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
17. 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 pinion gear. ST 498515500 REPLACER
18. Remove the front oil seal from differential carrier using ST. ST 398527700 PULLER ASSY
19. Remove the pilot bearing together with the front bearing cone and spacer using the ST. ST 398467700 DRIFT
20. When replacing the bearings, hit out the front bearing cup and rear bearing cup in this order using a brass bar.

VA2-TYPE

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

1. Tooth contact and backlash between hypoid driven gear and drive pinion
2. Total preload of drive pinion

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1. Set the ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT SET
2. Remove the oil drain plug and oil filler plug.
3. Remove the rear cover by removing retaining bolts. NOTE: Remove it by tapping with a plastic hammer.
4. Remove the air breather cap. NOTE: Do not attempt to replace the air breather cap unless necessary. Whenever the air breather cap is removed, replace it with a new part.
5. Remove the lock plate RH and LH.
6. 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
7. 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.
8. Remove the bearing race from side retainer RH and LH with ST and the press. NOTE: Be sure to turn the bolt of the ST by hand. Set the puller so that its claws catch the groove of side retainer. ST 18758AA000 PULLER
9. Remove the oil seal from side retainer RH and LH using a screwdriver. NOTE: Perform this operation only when changing oil seal.
10. Extract the bearing cone with ST1, ST2 and ST3. NOTE: Do not attempt to disassemble the parts unless necessary. Never mix up the RH and LH bearing races and cones. ST1 498077000 REMOVER ST2 399520105 SEAT ST3 899864100 REMOVER
11. Using the ST, loosen the hypoid driven gear bolt and remove the hypoid driven gear. ST 18270KA020 SOCKET (E20)
12. Remove the spring pin from hypoid driven gear side using ST. ST 899904100 STRAIGHT PIN REMOVER
13. Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers. NOTE: The gears should be marked or kept separated right and left, and front and rear as well as thrust washers.
14. Remove the circlip from the side gear.
15. Remove the self-locking nut while holding the companion flange with ST. ST 498427200 FLANGE WRENCH
16. Extract the companion flange using a puller.
17. Removes the drive pinion shaft.
18. 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 pinion gear. ST 398517700 REPLACER
19. Remove the front oil seal from differential carrier using screwdriver.
20. Remove the pilot bearing, front bearing cone and spacer.
21. When replacing the bearings, hit out the front bearing cup and rear bearing cup in this order using a brass bar.

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 seals and O-rings with new parts at every disassembly. Apply differential gear oil to the lips when installing the oil seal. Be careful not to mix up the differential oil seal RH and LH.

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1. Adjusting preload for front and rear bearings NOTE: Adjust the bearing preload between front and rear bearings with 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 398477702 DRIFT Install the front bearing race to the differential carrier using ST1 and ST2. ST1 398477701 HANDLE ST2 498447110 DRIFT Insert the front bearing cone. NOTE: Use new front bearing cone. Measure and record the thickness of the 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 ST1 into the case with the pinion height adjusting washer and rear bearing cone fitted onto it. NOTE: Use new rear bearing cone. Install the preload adjusting spacer and washer, front bearing cone, spacer, companion flange, and washer and self-locking nut. ST 498447150 DUMMY SHAFT ST 32285AA000 SPACER Turn the ST 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 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) THICKNESS SPECIFICATION Preload adjusting washer Part number 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 SPECIFICATION Preload adjusting spacer Part number 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)
2. Adjusting drive pinion height: Adjust the drive pinion height with washer installed between the rear bearing cone and the back of pinion gear. Attach the ST2. NOTE: At this time, install a pinion height adjusting washer, temporarily selected, or the same as that used before. ST1 498447150 DUMMY SHAFT ST2 498505501 DIFFERENTIAL CARRIER GAUGE ST 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 case 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) THICKNESS SPECIFICATION T Thickness of pinion height adjusting washer mm (in) To Thickness of washer temporarily inserted mm (in) N Clearance measured by 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) Thickness = 0.2 mm (0.0079 in) Therefore use part number 32295AA220. THICKNESS SPECIFICATION Pinion height adjusting washer Part number 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)
3. Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST. ST 498175500 INSTALLER
4. Insert the drive pinion into the differential carrier, and install the preselected preload adjusting spacer and washer.
5. Press-fit the front bearing cone into the carrier with ST1, ST2 and the spacer. ST1 399780104 WEIGHT ST2 899580100 INSTALLER ST 32285AA000 SPACER
6. Insert the spacer, then press-fit the pilot bearing with ST1 and ST2. ST1 399780104 WEIGHT ST2 899580100 INSTALLER
7. 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
8. Press-fit the companion flange with ST1 and ST2. NOTE: Be careful not to damage the bearing. ST1 899874100 INSTALLER ST2 399780104 WEIGHT
9. 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 self-locking nut, apply a sealing material to self-locking nut threads. 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
10. Check the initial torque or initial load. Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lb) Initial torque: 0.48 - 1.22 N.m (0.05 - 0.12 kgf-m, 0.35 - 0.90 ft-lb)
11. Assembling differential case Install the side gears and pinion mate gears, with their 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. Install the pinion mate shaft to the differential case by aligning the spring 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. THICKNESS SPECIFICATION Side gear thrust washer Part number 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 thrust washer surfaces. Attach the spring pin to the differential case. NOTE: Use new spring pin.
12. Install the hypoid driven gear to differential case. NOTE: Before installing bolts, apply a sealing material to bolt threads. SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) or equivalent Tighten diagonally. Tightening torque: 62 N.m (6.3 kgf-m, 45.7 ft-lb)
13. Using the ST, press-fit the side bearing to the differential case. ST 498485400 DRIFT
14. Assemble the side retainer. Install the oil seal into side retainer RH and LH. ST 498447100 INSTALLER Install the bearing race into side retainer RH and LH. CAUTION: Make sure that the RH and LH oil seals, 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.
15. 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 Back off the side retainer LH by approx. 1.5 teeth, and tighten the side retainer RH by approx. 2 teeth (amount that the side retainer LH is turned back (1.5) + 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 tooth. 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)
16. Put alignment marks on both the differential carrier and side retainer. Install O-rings to the side retainers one by one and restore the side retainers to the original positions.
17. Install the lock plate. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
18. Recheck the hypoid driven gear to pinion backlash. Backlash: 0.10 - 0.15 mm (0.004 - 0.006 in)
19. 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: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear. Flank contact Check item: Backlash 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. 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.
20. If correct tooth contact is not obtained, once again adjust the drive pinion height and the differential side bearing preload (already mentioned) and the hypoid gear backlash.
21. Install the gasket and the rear cover to the differential carrier. NOTE: Use a new gasket. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
22. Install the air breather cap. NOTE: Do not tap section (A) of the air breather cap. Be sure to tap section (B) to install.
23. Install the oil drain plug. NOTE: Use a new gasket. Tightening torque: 50 N.m (5.1 kg-m, 36.9 ft-lb)
24. Install the oil filler plug.

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. Attach tags not to mix up the RH and LH bearing races. Replace the oil seals and O-rings with new parts at every disassembly. Apply differential gear oil to the lips when installing the oil seal. Be careful not to mix up the differential oil seal RH and LH to be installed.

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Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

1. Adjusting preload for front and rear bearings NOTE: Adjust the bearing preload between front and rear bearings with 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 Using the ST, press-fit the front bearing race to the differential carrier. ST 499277200 INSTALLER Insert the front bearing cone. NOTE: Use new front bearing cone. Measure and record the thickness of pinion 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 ST1 into carrier with the pinion height adjusting washer and rear bearing cone fitted onto it. NOTE: Use new rear bearing cone. Install the preload adjusting spacer & washer, front bearing cone, spacer, companion flange, and washer & self-locking nut. ST1 18678AA000 DUMMY SHAFT 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. Be careful not to give excessive preload. When tightening the self-locking nut, lock companion flange with ST2 as shown in the figure. Measure the preload in direction of tangent to the flange. ST1 18678AA000 DUMMY SHAFT ST2 498427200 FLANGE WRENCH 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 lb) Initial torque: 0.48 - 1.22 N.m (0.05 - 0.12 kgf-m, 0.35 - 0.90 ft-lb) THICKNESS SPECIFICATION Preload adjusting washer Part number Thickness mm (in) 38336AA430 1.500 (0.0591) 38336AA440 1.513 (0.0596) 38336AA450 1.525 (0.0600) 38336AA460 1.538 (0.0606) 38336AA470 1.550 (0.0610) 38336AA480 1.563 (0.0615) 38336AA490 1.575 (0.0620) 38336AA500 1.588 (0.0625) 38336AA510 1.600 (0.0630) 38336AA520 1.613 (0.0635) 38336AA530 1.625 (0.0640) 38336AA540 1.638 (0.0645) 38336AA550 1.650 (0.0650) 38336AA560 1.663 (0.0655) 38336AA570 1.675 (0.0659) 38336AA580 1.688 (0.0665) 38336AA590 1.700 (0.0669) 38336AA600 1.713 (0.0674) 38336AA610 1.725 (0.0679) 38336AA620 1.738 (0.0684) 38336AA630 1.750 (0.0689) 38336AA640 1.763 (0.0694) 38336AA650 1.775 (0.0699) PRELOAD ADJUSTING SPACER SPECIFICATION Preload adjusting spacer Part number Length mm (in) 31454AA250 51.05 (2.010) 31454AA260 51.25 (2.018) 31454AA270 51.35 (2.022) 31454AA280 51.45 (2.026) 31454AA290 51.55 (2.030) 31454AA300 51.65 (2.033) 31454AA310 51.75 (2.037) 31454AA320 51.85 (2.041) 31454AA330 52.05 (2.049)
2. Adjusting drive pinion height: Adjust the drive pinion height with washer installed between the rear bearing cone and the back of pinion gear. Attach the ST2. ST1 18678AA000 DUMMY SHAFT ST2 18831AA010 DIFFERENTIAL CARRIER GAUGE Install the side retainer LH to the left side of the differential carrier in reverse direction. 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 case and ST2. ST1 18678AA000 DUMMY SHAFT ST2 18831AA010 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) PINION HEIGHT ADJUSTING WASHER THICKNESS SPECIFICATION T Thickness of pinion height adjusting washer mm (in) To Thickness of washer temporarily inserted mm (in) N Clearance measured by 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 mm (0.0059 in) + 0.1 mm (0.0039 in) - 0.05 mm (0.0020 in) = 0.2 mm (0.0079 in) Thickness = 0.2 mm (0.0079 in) Therefore use part number 32295AA370. PINION HEIGHT ADJUSTING WASHER THICKNESS SPECIFICATION Pinion height adjusting washer Part number Thickness mm (in) 32295AA350 0.150 (0.0059) 32295AA360 0.175 (0.0069) 32295AA370 0.200 (0.0079) 32295AA380 0.225 (0.0089) 32295AA390 0.250 (0.0098) 32295AA400 0.275 (0.0108)
3. Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST. ST 398177700 INSTALLER
4. Insert the drive pinion into the differential carrier, and install the preselected bearing preload adjusting spacer and washer.
5. Set ST and differential carrier to the press and install the front bearing cone. ST 399780104 WEIGHT NOTE: Set the carrier to the press until the companion flange is installed.
6. Insert the spacer, then install the pilot bearing.
7. 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 499277200 INSTALLER
8. Press-fit the companion flange with ST. NOTE: Be careful not to damage the bearing. ST 899874100 INSTALLER
9. 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
10. Install the self-locking nut while holding the companion flange with ST. Tightening torque: 191 N.m (19.5 kgf-m, 140.9 ft-lb) ST 498427200 FLANGE WRENCH
11. Measure the initial torque and initial load. Initial load: 12.7 - 32.2 N (1.3 - 3.3 kgf, 2.9 - 7.2 lb) Initial torque: 0.48 - 1.22 N.m (0.05 - 0.12 kgf-m, 0.35 - 0.90 ft-lb)
12. Assembling differential case Attach the circlip to the side gear. Install the side gears and pinion mate gears, with their 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. Install the pinion mate shaft to the differential case by aligning the spring pin holes. Measure the side gear backlash. Side gear backlash: 0.13 - 0.18 mm (0.005 - 0.007 in) Adjust the side gear backlash by selecting side gear thrust washer. SIDE GEAR THRUST WASHER THICKNESS SPECIFICATION Side gear thrust washer Part number Thickness mm (in) 803038021 0.950 (0.0374) 803038022 1.000 (0.0394) 803038023 1.050 (0.0413) Check the condition of rotation after applying oil to the gear tooth surfaces and thrust washer surfaces. Attach the spring pin to the differential case. NOTE: Use new spring pin.
13. Install the hypoid driven gear to differential case. NOTE: Set a cushioning such as wooden block, aluminum plate or shop cloth between vise and differential case if the side gear comes into contact with vise. Before installing bolts, apply a sealing material to bolt threads. SEAL MATERIAL: THREE BOND 1324 (Part No. 004403042) or equivalent Tighten diagonally. 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 ST, further tighten the hypoid driven gear mounting bolts. Tightening angle: 33° ± 2° ST 18554AA000 ANGLE GAUGE
14. Using the ST, press-fit the side bearing to the differential case. ST 398487700 DRIFT
15. Assemble the side retainer. Install the oil seal into side retainer RH and LH. CAUTION: Make sure that the oil seals and side retainers are properly assembled. NOTE: Use a new oil seal. 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 398417700 DRIFT Install the differential 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.
16. 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 Back off the side retainer LH by approx. 1.5 teeth, and tighten the side retainer RH by approx. 2 teeth (amount that the side retainer LH is turned back (1.5) + 1/2 teeth). NOTE: 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 attach the lock plate. NOTE: Turn over the lock plate to shift the holder by 1/2 tooth. 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)
17. Put alignment marks on both the differential carrier and side retainer. Remove the side retainer side at a time. Replace them in the original position after inserting an O-ring and applying differential gear oil to the threaded portion.
18. Tighten the bolt of lock plate to specified torque. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
19. Recheck the hypoid driven gear to pinion backlash. Backlash: 0.10 - 0.15 mm (0.004 - 0.006 in)
20. 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. 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.
21. If correct tooth contact is not obtained, once again adjust the drive pinion height and the differential side bearing preload (already mentioned) and the hypoid gear backlash.
22. Install the gasket and the rear cover to the differential carrier. NOTE: Use a new gasket. Tightening torque: 34 N.m (3.5 kgf-m, 25.1 ft-lb)
23. Install the air breather cap. NOTE: Do not tap section (A) of the air breather cap. Be sure to tap section (B) to install.
24. Install the oil drain plug. NOTE: Use a new gasket. Tightening torque: 50 N.m (5.1 kgf-m, 36.9 ft-lb)
25. Install the filler plug.

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

Side gear backlash

VA1-type: 0.05 - 0.15 mm (0.002 - 0.006 in)

VA2-type: 0.13 - 0.18 mm (0.005 - 0.007 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.

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 not within the specification, adjust the side bearing preload or repair if necessary.

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

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 even 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 (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 electronic 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. (In the case of a push button start, press the push button ignition switch twice without stepping on the brake.)
6. Select {AT related learning & inspecting mode} in the «Transmission Diagnosis» screen of the Subaru Select Monitor.
7. Select {Rear differential inspection mode} in the «Learning and inspection mode related to AT» display screen of the Subaru Select Monitor.
8. Follow the messages displayed on the Subaru Select Monitor screen when working.
9. The results of the rear differential inspection mode are displayed on the Subaru Select Monitor screen. When ended normally: «Rear differential has been replaced successfully.» When ended abnormally: «Rear differential error is detected. Check the items for rear differential installation again.» When interrupted: «Inspection interrupted. Start this inspection mode over again from the beginning.»
10. After the message «Inspection completed. Turn off the IG SW.» appears, the rear differential inspection mode completes. NOTE: For details concerning the operation procedure, 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 inspection mode ends abnormally, the front differential and rear differential may be different from the specifications for the vehicle. When the inspection mode is interrupted, the following reasons are possible. ABNORMAL TERMINATION REASONS Message Main reasons for abnormal termination "Inspection interrupted." «Inspection interrupted. Start this inspection mode over again 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 canceled." The model does not support the rear differential inspection mode. TCM has detected a failure. Inspect according to the information. TCM has detected a failure.
11. Perform "Function Check Sequence" for VDC. Ref. to «FUNCTION CHECK»(ref-371926-S39173692322010091900000) , OPERATION, Subaru Select Monitor. Ref. to «ADJUSTMENT»(ref-371945-S24840065522010091900000) , VDC Control Module and Hydraulic Control Unit (VDCCM&H/U).