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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.
    Fig 1: Installing Bevel Gear, Pinion Shaft And Bevel Pinion
    G04991004Courtesy 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. < Ref. 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

    Standard backlash: 

    0.13 - 0.18 mm (0.0051 - 0.0071 in) 

    Fig 2: Measuring Backlash Between Bevel Gear And Pinion
    G05003114Courtesy 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

    Fig 3: Identifying Pinion Shaft, Differential Case And Straight Pin
    G04991006Courtesy 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).
    • Be careful because the roller bearing outer races are used as a set.

    ST1 499277100 BUSH 1-2 INSTALLER

    ST2 398497701 ADAPTER

    Fig 4: Identifying Bush 1-2 Installer ST1 499277100 And Adapter ST2 398497701
    G05003116Courtesy of SUBARU OF AMERICA, INC.
  5. Install the hypoid driven gear to differential case using twelve bolts.

    Tightening torque: 

    T: 62 N.m (6.3 kgf-m, 45.6 ft-lb) 

    Fig 5: Identifying Hypoid Driven Gear And Differential Case
    G04991008Courtesy of SUBARU OF AMERICA, INC.
  6. Set the drive axle shaft into differential case and hold it using outer spring. Measure the shaft to case clearance to check if it is within specifications using thickness gauge. (Non-TURBO model)
    NOTE: Replace the snap ring with suitable one, if the measurement is not within specifications.
    SNAP RING (OUTER) THICKNESS SPECIFICATION

    Snap ring (Outer)
    Part No. Thickness mm (in)
    805028011 1.05(0.0413)
    805028012 1.20(0.0472)

    Clearance 

    0 - 0.2 mm (0 - 0.008 in) 

    Fig 6: Measuring Shaft To Case Clearance
    G05003118Courtesy of SUBARU OF AMERICA, INC.
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