A/t & M/t Differentials: Other Subaru Outback BR рестайлинг

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. For option code, refer to IDENTIFICATION .

REAR DIFFERENTIAL GEAR OIL

Recommended gear oil

GL-5 (75W-90) or equivalent

Scheme 91

SERVICE DATA

Scheme 92

Tightening torque: N.m (kgf-m, ft-lb)

T1: 10.5 (1.1, 7.7)

T2: 29.5 (3.0, 21.8)

T3: 49 (5.0, 36.1)

T4: 103 (10.5, 76.0)

T5: 181.5 (18.5, 133.9)

Scheme 93

Tightening torque: N.m (kgf-m, ft-lb)

T1: 25 (2.5, 18.4)

T2: 50 (5.1, 36.9)

T3: Refer to ASSEMBLY .

T4: 191 (19.5, 140.9)

Scheme 94

Tightening torque: N.m (kgf-m, ft-lb)

T1: 25 (2.5, 18.4)

T2: 34 (3.5, 25.1)

T3: 50 (5.1, 36.9)

T4: Refer to ASSEMBLY .

T5: 191 (19.5, 140.9)

Scheme 95

Tightening torque: N.m (kgf-m, ft-lb)

T1: 50 (5.1, 36.9)

T2: 70 (7.1, 51.6)

T3: 110 (11.2, 81.1)

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

Scheme 96

Scheme 97

Scheme 98

1. Lift up the vehicle.
2. Remove the filler plug, and then check the gear oil. Replace the gear oil if it is contaminated, deteriorated or cloudy. Refer to «REPLACEMENT»(ref-565172-S09238729222013071000000) .
3. Check that the gear oil level is within -5 mm (-0.2 in) from the bottom of the filler plug hole. If the level is low, make sure that there is no oil leakage and refill up to the bottom of 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 filler plug. This is at normal level, requiring no oil refill. T-type VA1-type VA2-type
4. Install the filler plug. NOTE: For the T-type, apply liquid gasket to the filler plug. Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent For VA type, use a new gasket. Tightening torque: T-type: 49 N.m (5.0 kgf-m, 36.1 ft-lb) VA-type: 50 N.m (5.1 kgf-m, 36.9 ft-lb)

CVT MODEL

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

AT MODEL

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

MT MODEL

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

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

1. Shift the select lever or gear shift lever to neutral.
2. Release the parking brake.
3. Disconnect the ground cable from battery.
4. Loosen the wheel nuts.
5. Lift up the vehicle.
6. Remove the rear wheels.
7. Drain differential gear oil. Refer to «REPLACEMENT»(ref-565172-S09238729222013071000000) .
8. Remove the rear exhaust pipe. 2.5 L model Refer to «REMOVAL»(ref-565184-S13103619792013071000000) . 3.6 L model Refer to «REMOVAL»(ref-565201-S14922056002013071000000) .
9. Remove the heat shield cover.
10. Remove the propeller shaft. Refer to «REMOVAL»(ref-565177-S36474058612013071000000) .
11. Loosen the self-lock nuts which hold the rear differential to rear crossmember.
12. 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. When removing the DOJ from the rear differential, fit the tire lever or ST to the bolts as shown in the figure so as not to damage the side retainer. T-type ST 28099PA100 DRIVE SHAFT REMOVER VA-type
13. Set the rear differential to transmission jack.
14. Remove the rear differential front member.
15. Remove the self-locking nuts which hold the rear differential to the crossmember.
16. Pull out 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.
17. Lower the transmission jack.
18. Pull out the rear drive shaft from the rear differential. NOTE: If it is difficult to pull out the rear drive 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 rear drive shaft for VA2-type, remove the differential case assembly and replace it with a new part.
19. Lower the transmission jack.
20. Secure the rear drive shaft to rear lateral link using wire.
21. Remove the rear differential member plate from rear differential.

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

1. Attach 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 drive 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 DOJ 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. 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)
12. Remove the transmission jack.
13. Install the propeller shaft. Refer to «INSTALLATION»(ref-565177-S15615832782013071000000) .
14. Install the heat shield cover. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
15. Install the rear exhaust pipe. 2.5 L model Refer to «INSTALLATION»(ref-565184-S10239718472013071000000) . 3.6 L model Refer to «INSTALLATION»(ref-565201-S00442187542013071000000) .
16. Fill differential gear oil. Refer to «REPLACEMENT»(ref-565172-S09238729222013071000000) .
17. Installing procedure hereafter is in the reverse order of removal.
18. Perform "Rear differential inspection mode" using the Subaru Select Monitor. (CVT model) Refer to «REAR DIFFERENTIAL INSPECTION MODE»(ref-565172-S13660654842013071000000) . 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.

Scheme 116

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 outside the specification range, adjust the side bearing preload and 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 on its back surface exceeds the limit, 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. Refer to ASSEMBLY .

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.

Scheme 117

Scheme 118

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. Refer to ASSEMBLY .

Adjust hypoid driven gear backlash. Refer to ASSEMBLY .

Adjust the tooth contact between hypoid driven gear and drive pinion gear. Refer to ASSEMBLY .

Adjust the side retainer shim. Refer to ASSEMBLY .

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

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

1. Set the ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT SET
2. Remove the drain plug and 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 remove 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 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. Remove the O-ring.
11. 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
12. Using the ST, loosen the hypoid driven gear bolt and remove the hypoid driven gear. ST 18270KA020 SOCKET (E20)
13. Remove the spring pin from hypoid driven gear side using ST. ST 899904100 STRAIGHT PIN REMOVER
14. 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.
15. Remove the self-locking nut while securing the companion flange with ST. ST 498427200 FLANGE WRENCH
16. Extract the companion flange with a puller.
17. 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
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 bearing cone. ST 498515500 REPLACER
19. Remove the front oil seal from differential carrier using ST. ST 398527700 PULLER ASSY
20. Remove the pilot bearing together with the front bearing cone and spacer using the ST. ST 398467700 DRIFT
21. 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

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

1. Set the ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT SET
2. Remove the drain plug and 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 remove 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 the RH and LH side retainers using a screwdriver. NOTE: Perform this operation only when changing oil seal.
10. Remove the O-ring.
11. 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
12. Using the ST, loosen the hypoid driven gear bolt and remove the hypoid driven gear. ST 18270KA020 SOCKET (E20)
13. Remove the spring pin from hypoid driven gear side using ST. ST 899904100 STRAIGHT PIN REMOVER
14. 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.
15. Remove the circlip from the side gear.
16. Remove the self-locking nut while securing the companion flange with ST. ST 498427200 FLANGE WRENCH
17. Extract the companion flange using a puller.
18. Remove the drive pinion shaft.
19. 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
20. Remove the front oil seal from differential carrier using screwdriver.
21. Remove the pilot bearing, front bearing cone and spacer.
22. 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.

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

1. 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. 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. NOTE: Use new rear bearing cone. Install the preload adjusting spacer, washer, front bearing cone, spacer, pilot bearing, companion flange, and self-locking nut. 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) Preload adjusting washer Part No. Thickness mm (in) 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)
2. 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)
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 Part No. 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 pilot 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 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
10. 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)
11. 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 side gear 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.
12. 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 ST, further tighten the hypoid driven gear mounting bolts. Tightening angle: 35°±2° ST 18554AA000 ANGLE GAUGE
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. 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.
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 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)
16. 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.
17. 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)
18. Recheck the backlash between hypoid driven gear and drive pinion. 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: 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.
20. 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.
21. 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)
22. 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.
23. Install the drain plug. NOTE: Use a new gasket. Tightening torque: 50 N.m (5.1 kg-m, 36.9 ft-lb)
24. 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. Refer to «REPLACEMENT»(ref-565172-S09238729222013071000000) .

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 seal and O-ring with a new part at every disassembly. Apply differential gear oil to the lips when installing the oil seal.

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

1. 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 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 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 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, pilot bearing, companion flange, and 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. Measure the preload in direction of tangent to the flange. Be careful not to give excessive preload. When tightening the self-locking nut, lock companion flange with ST2 as shown in the figure. 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 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) 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 Part No. 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 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 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 differential carrier 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) 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 mm (0.0059 in) + 0.1 mm (0.0039 in) - 0.05 mm (0.0020 in) = 0.2 mm (0.0079 in) Result: Thickness = 0.2 mm (0.0079 in) Therefore use part number 32295AA370. Pinion height adjusting washer Part No. 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 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. 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)
12. Assembling differential case Attach the circlip to the side gear. 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. Measure the side gear backlash. Side gear backlash: 0.13 - 0.18 mm (0.005 - 0.007 in) Adjust the side gear backlash as specified by selecting side gear thrust washer. Side gear thrust washer Part No. 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 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 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 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. NOTE: Use a new oil seal. Apply differential gear oil to the oil seal lip. ST 398437700 DRIFT 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 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.
16. Perform the backlash adjustment between the hypoid driven gear and drive pinion, and side bearing preload adjustment. 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 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]. 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 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 the backlash adjustment between hypoid driven gear and drive pinion, 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 retainers one side at a time. After installing an O-ring and applying differential gear oil to the threaded portion, restore them to the original position.
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, readjust the drive pinion height and the differential side bearing preload (already mentioned) and the hypoid gear backlash.
22. Install the gasket and rear cover to the differential carrier, and tighten the bolts to specified torque. 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: When installing the air breather cap, do not tap section (A). Be sure to tap section (B) to install.
24. Install the 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. 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. Refer to «REPLACEMENT»(ref-565172-S09238729222013071000000) .

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 outside the specification range, 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 outside the specification range, adjust the side bearing preload and repair if necessary.

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.

Inspect the tooth contact between the hypoid driven gear and drive pinion. Refer to ASSEMBLY .

Adjust the side gear backlash. Refer to ASSEMBLY .

Adjust hypoid driven gear backlash. Refer to ASSEMBLY .

Adjust the tooth contact between hypoid driven gear and drive pinion gear. Refer to ASSEMBLY .

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. (For model with push button start, press the push button ignition switch twice without depressing brake pedal.)
6. Select {Work Support} in the «Transmission Control System» screen of Subaru Select Monitor.
7. Select {Maintenance mode} in the «Work Support» screen of Subaru Select Monitor.
8. Select {Rear differential inspection mode} in the «Maintenance mode» screen of the Subaru Select Monitor.
9. Follow the messages displayed on the Subaru Select Monitor screen when working.
10. The results of the rear differential inspection mode are displayed on the Subaru Select Monitor screen. When ended normally: "The rear differential has been replaced normally." When ended abnormally: "A rear differential abnormality has been detected. Reinspect the items at the time of rear differential installation." When interrupted: "Inspection is stopped. Restart this inspection mode from the beginning."
11. After the message "Inspection has been completed. Set the ignition switch to OFF." appears, the rear differential inspection mode completes. NOTE: When the rear differential inspection mode is completed properly, the following warning lights may illuminate. But this is not a malfunction. If warning light illuminates, clear the memory. VDC/ABS, engine, power steering, EyeSight For detailed operation procedures, 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 rear differential inspection mode ends abnormally, the front differential and rear differential may be different from the specifications for the vehicle. When the rear differential inspection mode is interrupted, the following reasons are possible. Message Main reasons for abnormal termination "Inspection is stopped." "Inspection is stopped. Restart this inspection mode 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 is stopped." The model does not support the rear differential inspection mode. The TCM has detected a fault. Inspect following the information. TCM has detected a failure.
12. Perform "Function Check Sequence" for VDC. Refer to «FUNCTION CHECK»(ref-565192-S02854948172013071000000) . Refer to «ADJUSTMENT»(ref-565186-S16232332342013071000000) .