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Front Differential Assembly: Adjustment

  1. Using the ST, screw-in the 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 Retainer
    G03831412Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the oil pump housing.
  3. Remove the liquid gasket completely.
  4. Install the oil pump housing assembly to converter case, and secure them with tightening four bolts evenly.
    NOTE: Use an old gasket or an aluminum washer so as not to damage the mating surface of housing.

    Tightening torque: 

    41 N.m (4.2 kgf-m, 30.4 ft-lb) 

    Fig 2: Removing Liquid Gasket
    G03831413Courtesy of SUBARU OF AMERICA, INC.
  5. Rotate the drive pinion several times using ST1 and ST2.

    ST1 498937110 HOLDER

    ST2 499787700 WRENCH

    Fig 3: Rotating Drive Pinion
    G03831414Courtesy of SUBARU OF AMERICA, INC.
  6. Tighten the retainer LH until contact is felt while rotating the shaft. Then loosen the retainer RH. Keep tightening the retainer LH, and loosening the retainer RH until the pinion shaft cannot be turned. This is the "zero" state.
    Fig 4: Identifying Retainer
    G03831415Courtesy of SUBARU OF AMERICA, INC.
  7. After the "zero" state is established, back off the retainer LH 3 notches and secure it with the lock plate. Then back off the retainer RH and retighten until it stops. Rotate the drive pinion few times. Tighten the retainer RH 1-3/4 notches further. This sets the preload. Finally, secure the retainer with its lock plate.
    Fig 5: Identifying Lock Plate
    G03831416Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Turning the retainer by one tooth changes the backlash about 0.05 mm (0.0020 in).
    Fig 6: Turning Retainer
    G03831417Courtesy of SUBARU OF AMERICA, INC.
  8. Install the SUBARU genuine axle shaft to both side of front differential part.

    Parts No. 38415AA000 AXLE SHAFT

  9. Turn the drive pinion several times with ST1 and check to see if the backlash is within the specified 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: Installing Axle Shaft
    G03831418Courtesy of SUBARU OF AMERICA, INC.
  10. Adjust the tooth contact between front differential and drive shaft. < Ref. to , ADJUSTMENT , Drive Pinion Shaft Assembly. >
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