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Front Differential: Installation

  1. 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
    G03483811Courtesy of SUBARU OF AMERICA, INC.
  2. Install the new circlip to the axle shaft, insert the shaft into the differential assembly, and tap it into position with a plastic hammer.
    NOTE: If no play is felt, check whether the shaft is fully inserted. If shaft insertion is correct, replace the axle shaft.

    Thrust play: 

    0.3 - 0.5 mm (0.012 - 0.020 in) 

  3. Wrap vinyl tape around the splined portion of the axle shaft.
    Fig 2: Identifying Wrap Vinyl Tape Around Splined Portion Of Axle Shaft
    G03483812Courtesy of SUBARU OF AMERICA, INC.
  4. 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.
    NOTE:
    • 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.
  5. Using ST, install the side retainers. Refer to ADJUSTMENT  , Front Differential.

    ST 499787000 WRENCH ASSY

  6. Install the lock plate.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.1 ft-lb) 

    Fig 3: Installing Lock Plate
    G03483813Courtesy of SUBARU OF AMERICA, INC.
  7. Install the new seal pipe to the torque converter clutch case.
    Fig 4: Installing New Seal Pipe To Torque Converter Clutch Case
    G03483814Courtesy of SUBARU OF AMERICA, INC.
  8. Install the torque converter clutch case to transmission case. Refer to INSTALLATION  , Torque Converter Clutch Case.
  9. Install air breather hose.
  10. Insert inhibitor switch and transmission connector into stay.
    Fig 5: Inserting Inhibitor Switch And Transmission Connector Into Stay
    G03483815Courtesy of SUBARU OF AMERICA, INC.
  11. Install oil cooler pipes. Refer to INSTALLATION  , Oil Cooler Pipes.
  12. Install the oil charger pipe with O-ring Refer to INSTALLATION  , Oil Charger Pipe.
  13. Insert the input shaft while turning lightly by hand.
    NOTE: Be careful not to damage the bushing.

    Normal protrusion A: 

    50 - 55 mm (1.97 - 2.17 in) 

    Fig 6: Inserting Input Shaft
    G03483816Courtesy of SUBARU OF AMERICA, INC.
  14. Install the torque converter clutch assembly. Refer to INSTALLATION  , Torque Converter Clutch Assembly.
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