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Differential Case Assembly

  1. Install the bevel gear and bevel pinion together with washers, and insert pinion shaft.
    NOTE: Face the chamfered side of washer toward gear.
    2. Fig 1: Installing Bevel Gear & Bevel Pinion Together With Washers
    G02093758Courtesy of SUBARU OF AMERICA, INC.
  2. Measure the backlash between bevel gear and pinion. If it is not within specifications, install a suitable washer to adjust it. Refer to ADJUSTMENT , Front Differential Assembly.
    NOTE: Be sure the pinion gear tooth contacts adjacent gear teeth during measurement.

    ST1 498247001 MAGNET BASE

    ST2 498247100 DIAL GAUGE

    1. Standard backlash:  0.13 - 0.18 mm (0.0051 - 0.0071 in)
    3. Fig 2: Measuring Backlash Between Bevel Gear & Pinion
    G02093759Courtesy of SUBARU OF AMERICA, INC.
  3. Align the pinion shaft and differential case at their holes, and drive the straight pin into holes from the hypoid driven gear side, using ST.
    NOTE: Lock the straight pin after installing.

    ST 899904100 REMOVER

    4. Fig 3: Driving Straight Pin Into Holes From Hypoid Driven Gear Side
    G02093760Courtesy of SUBARU OF AMERICA, INC.
  4. Install the 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).
    NOTE: Be careful because the roller bearing outer races are used as a set.

    ST1 499277100 BUSH 1-2 INSTALLER

    ST2 398497701 ADAPTER

    5. Fig 4: Installing Roller Bearing To Differential Case
    G02093761Courtesy of SUBARU OF AMERICA, INC.
  5. Install the hypoid driven gear to differential case using twelve bolts.

    Tightening torque: 

    1. T:  62 N.m (6.3 kgf-m, 45.6 ft-lb)
    6. Fig 5: Installing Hypoid Driven Gear To Differential Case
    G02093762Courtesy of SUBARU OF AMERICA, INC.
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