Front Differential: Installation

WARNING: This page is about a different car, the 2001 Subaru Outback, 2001 Subaru Legacy, 2001 Subaru Impreza, and 2001 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.

Install the differential assembly to the case, paying special attention not to damage the inside of the case (particularly, the differential side retainer contact surface).

Fig 1: Installing Differential Assembly
Install the circlip to the axle shaft, insert the shaft into the differential assembly, and tap it into position with a plastic hammer.
CAUTION:
- If no play is felt, check whether the shaft is fully inserted. If shaft insertion is correct, replace the axle shaft.
- Be sure to use a new circlip.
Thrust play:
1. 0.3 - 0.5 mm (0.012 - 0.020 in)
Wrap vinyl tape around the splined portion of the axle shaft.

Fig 2: Wrapping Splined Portion Of Axle Shaft With Vinyl Tape
Install the oil seal and outer race (taper roller bearing) to the differential side retainer. Then screw in the retainer and the O-ring after coating the threads with oil.
CAUTION:
- Pay attention not to damage the oil seal lips.
- Do not confuse the RH and LH oil seals.
- Keep the O-ring removed from the retainer.
Using ST, install the side retainers. See ADJUSTMENT .
ST 499787000 WRENCH ASSY
Install the lock plate.
Tightening torque:
1. 25 N.m (2.5 kgf-m, 18.1 ft-lb)
Fig 3: Installing Side Bearing Retainers
Install the seal pipe to the torque converter clutch case.
CAUTION: Be sure to use a new seal pipe.

Fig 4: Installing Seal Pipe To Torque Converter Clutch Case
Install the rubber seal to the torque converter clutch case.
CAUTION: Be careful not to lose the rubber seal.

Fig 5: Installing Rubber Seal To Torque Converter Clutch Case
Apply proper amount of liquid gasket to the entire torque converter clutch case mating surface.
Liquid gasket:
1. THREE BOND 1215
NOTE: Make sure that the rubber seal and seal pipe are fitted in position.

Fig 6: Applying Liquid Gasket To Torque Converter Clutch Case Mating Surface
Install the torque converter clutch case assembly to the transmission case assembly, and secure with six bolts and four nuts.
CAUTION: When installing, be careful not to damage the torque converter clutch case bushing and oil seal.

Tightening torque:
1. 41 N.m (4.2 kg-m, 30.4 ft-lb)
Fig 7: Installing Torque Converter Clutch Case Assembly To Transmission Case Assembly
Install air breather hose.
Insert inhibitor switch and transmission connector into stay.

Fig 8: Inserting Inhibitor Switch & Transmission Connector
Install oil cooler pipes. See INSTALLATION .
Install the oil charger pipe with O-ring. See INSTALLATION .
Insert the input shaft while turning lightly by hand.
CAUTION: Be careful not to damage the bushing.

Normal protrusion A:
1. 50 - 55 mm (1.97 - 2.17 in)
Fig 9: Identifying Protrusion "A"
Install the torque converter clutch assembly. See INSTALLATION .