FixVault
Home › Subaru › 2003 › Baja Standard › Repair and Diagnosis › Transmission › Manual Trans › Manual Trans & Differential › Front Differential Assembly › Assembly › Differential Case Assembly

Differential Case Assembly

  1. Install bevel gear and bevel pinion together with washers, and insert pinion shaft.
    NOTE: Face the chamfered side of washer toward gear.
    Fig 1: Installing Bevel Gear & Bevel Pinion With Washers
    G02876489Courtesy of SUBARU OF AMERICA, INC.
  2. Measure backlash between bevel gear and pinion. If it is not within specifications, install a suitable washer to adjust it. < Ref. to ADJUSTMENT , Front Differential Assembly.>
    NOTE: Be sure the pinion gear tooth contacts adjacent gear teeth during measurement.
    1. ST1 498247001 MAGNET BASE
    2. ST2 498247100 DIAL GAUGE
    1. Standard backlash:   0.13 - 0.18 mm (0.0051 - 0.0071 in)
    Fig 2: Measuring Backlash Between Bevel Gear & Pinion
    G02876490Courtesy of SUBARU OF AMERICA, INC.
  3. Align pinion shaft and differential case at their holes, and drive straight pin into holes from the hypoid driven gear side, using ST.
    NOTE: Lock straight pin after installing.
    1. ST 899904100 REMOVER
    Fig 3: Aligning Pinion Shaft & Differential Case
    G02876491Courtesy of SUBARU OF AMERICA, INC.
  4. Install roller bearing to differential case.
    NOTE:
    • Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
    • Be careful because roller bearing outer races are used as a set.
    1. ST1 499277100 BUSHING 1-2 INSTALLER
    2. ST2 398497701 ADAPTER
    Fig 4: Installing Roller Bearing To Differential Case
    G02876492Courtesy of SUBARU OF AMERICA, INC.
  5. Install hypoid driven gear to differential case using twelve bolts.

    Tightening torque: 

    1. T:  62 N.m (6.3 kgf-m, 45.6 ft-lb)
    Fig 5: Installing Hypoid Driven Gear To Differential Case
    G02876493Courtesy of SUBARU OF AMERICA, INC.
  6. Position drive axle shaft in differential case and hold it outer snap ring (289). Using a thickness gauge, confirm whether clearance between the shaft and case is within specifications.
    NOTE: If it is not within specifications, replace snap ring with a suitable one.
    1. Clearance:  0 - 0.25 mm (0 - 0.0098 in)
    Fig 6: Measuring Clearance Between Shaft & Case
    G02876494Courtesy of SUBARU OF AMERICA, INC.
    SNAP RING (OUTER-28) THICKNESS CHART

    Snap ring (Outer-28)
    Part No. Thickness mm (in)
    805028011 1.05 (0. 0413)
    804018012 1.20 (0. 0472)
About FixVault