Differential Case Assembly

Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH). Insert the pinion shaft.
Install straight pin from reverse direction.

Fig 1: Installing Straight Pin
Courtesy of SUBARU OF AMERICA, INC.
Install the washer and differential bevel gear to the differential case (LH). Then put the case over the differential case (RH), and connect both cases.
Install the hypoid driven gear and secure by tightening the bolt.
Standard tightening torque:

62 N.m (6.3 kgf-m, 46 ft-lb)

Fig 2: Installing Hypoid Driven Gear
Courtesy of SUBARU OF AMERICA, INC.

Measurement of backlash (Selection of washer)

Install the SUBARU genuine axle shaft to differential case.
Part No. 38415AA070 AXLE SHAFT
Measure the gear backlash with ST1 and ST2, and insert ST2 through the access window of the case.
ST1 498247001 MAGNET BASE

ST2 498247100 DIAL GAUGE
NOTE:
- Measure the backlash by applying a pinion tooth between two bevel gear teeth.
- Fix bevel pinion gear in place with a screwdriver or similar tool when measuring.
Standard value:

0.13 - 0.18 mm (0.0051 - 0.0071 in)

Fig 3: Measuring Backlash
Courtesy of SUBARU OF AMERICA, INC.

If backlash is not as specified, select a washer from the table shown in WASHER THICKNESS CHART .

WASHER THICKNESS CHART

Using ST, install taper roller bearing.
ST 398437700 DRIFT

Fig 4: Installing Taper Roller Bearing Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.