Front Differential Assembly: Adjustment

Using ST, screw in the differential side retainer until light contact is felt.
NOTE: Screw in the RH side slightly deeper than the LH side.

ST 499787000 WRENCH ASSY

Fig 1: Screwing In Differential Side Retainer Using Wrench Assy ST 499787000
Courtesy of SUBARU OF AMERICA, INC.
Remove the oil pump housing.
Thoroughly remove the liquid gasket from the case mating surface beforehand.
Install the oil pump housing assembly to the converter case, and secure evenly by tightening four bolts.
NOTE: Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing.

Tightening torque:

41 N.m (4.2 kgf-m, 30.4 ft-lb)

Fig 2: Installing Oil Pump Housing Assembly
Courtesy of SUBARU OF AMERICA, INC.
Rotate the drive pinion several times with ST1 and ST2.
ST1 498937110 HOLDER

ST2 499787700 WRENCH

Fig 3: Rotating Drive Pinion Using Holder ST1 498937110 And Wrench ST2 499787700
Courtesy of SUBARU OF AMERICA, INC.
Tighten the LH differential side retainer until contact is felt while rotating the shaft. Then loosen the RH differential side retainer. Keep tightening the LH differential side retainer and loosening the RH differential side retainer until the pinion shaft can no longer be turned. This is the "zero" state.

Fig 4: Tightening Differential Side Retainer
Courtesy of SUBARU OF AMERICA, INC.
After the "zero" state is established, back off the LH differential side retainer 3 notches and secure it with the lock plate. Then back off the RH differential side retainer and retighten until it stops. Rotate drive pinion a few times. Tighten the RH differential side retainer 1-3/4 notches further. This sets the preload. Finally, secure the differential side retainer with its lock plate.

Fig 5: Identifying Lock Plate
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Turning the differential side retainer by one tooth changes the backlash about 0.05 mm (0.0020 in).

Fig 6: Turning Differential Side Retainer
Courtesy of SUBARU OF AMERICA, INC.
Turn the drive pinion several rotations with ST1 and check to see if the backlash is within the standard value with ST2, ST3, ST4 and ST5.
ST1 499787700 WRENCH

ST2 498247001 MAGNET BASE

ST3 498247100 DIAL GAUGE

ST4 499787500 ADAPTER

ST5 498255400 PLATE

Backlash:

0.13 - 0.18 mm (0.0051 - 0.0071 in)

Fig 7: Turning Drive Pinion Several Rotations Using Wrench ST1 499787700, Magnet Base ST2 498247001, Dial Gauge ST3 498247100, Adapter ST4 499787500, Plate ST5 498255400
Courtesy of SUBARU OF AMERICA, INC.
Adjust the tooth contact between front differential and drive shaft. < Ref. to ADJUSTMENT , Drive Pinion Shaft. >