VA1-TYPE Subaru Outback BS

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

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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.