Differential Case Assembly

1. Install the differential bevel gear and differential bevel pinion together with adjusting washer, and insert the pinion shaft.
   NOTE: Face the chamfered side of adjusting washer toward bevel gear.
   Fig 1: Pinion Shaft, Differential Bevel Pinion, Differential Bevel Gear And Adjusting Washer

   Courtesy of SUBARU OF AMERICA, INC.
2. Measure the backlash between the differential bevel gear and differential bevel pinion. Adjust the backlash if not within specified limit. Ref. to DIFFERENTIAL BEVEL PINION GEAR BACKLASH , ADJUSTMENT, Front Differential Assembly.
   NOTE: Be sure the bevel pinion gear teeth contact adjacent gear teeth during measurement.

   Standard backlash 

   0.13 - 0.18 mm (0.0051 - 0.0071 in) 

   ST1 498247001 MAGNET BASE

   ST2 498247100 DIAL GAUGE

   Fig 2: Measuring Backlash Between Differential Bevel Gear And Differential Bevel Pinion

   Courtesy of SUBARU OF AMERICA, INC.
3. Align the pinion shaft and differential case with each hole, and drive the straight pin into the holes from the hypoid driven gear side using the ST.
   NOTE: Use a new straight pin. After driving, crimp the area around the hole, and make sure that the straight pin will not come out.

   ST 899904100 STRAIGHT PIN REMOVER

   Fig 3: Driving Straight Pin Into Holes From Hypoid Driven Gear Side

   Courtesy of SUBARU OF AMERICA, INC.
4. Install the taper roller bearing.
   CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
   NOTE: Be careful when handling because the taper roller bearing and the outer race are used as a set.

   ST1 499277100 BUSHING 1-2 INSTALLER

   ST2 398497701 SEAT

   Fig 4: Installing Taper Roller Bearing

   Courtesy of SUBARU OF AMERICA, INC.
5. Install the hypoid driven gear using twelve bolts.

Tightening torque: 

T: 62 N.m (6.3 kgf-m, 45.7 ft-lb) 

Fig 5: Hypoid Driven Gear, Differential Case And Bolt (With Torque Specification)

Courtesy of SUBARU OF AMERICA, INC.