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Front Differential Assembly: Installation

  1. Install the differential assembly to the clutch housing.
  2. Apply oil to the screw threads of the differential side retainer.
  3. Remove the O-rings on both sides of the differential side retainer.
  4. Install the differential side retainers to both sides, using the ST.

    ST1 18658AA021 WRENCH COMPL RETAINER (RH SIDE) 

    ST2 18630AA000 WRENCH ASSY (LH SIDE) 

    NOTE: Be careful not to damage the oil seal.
  5. Inspect and adjust the hypoid driven gear backlash. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) (TY85)>FRONT DIFFERENTIAL ASSEMBLY>INSPECTION>HYPOID DRIVEN GEAR BACKLASH .
  6. Inspect and adjust the tooth contact. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) (TY85)>DRIVE PINION SHAFT ASSEMBLY>ADJUSTMENT .
  7. Mark the mating positions of the left and right differential side retainers and the clutch housing.
    G05003503Courtesy of SUBARU OF AMERICA, INC.
  8. Remove the differential side retainers from both sides.
    NOTE: When removing the side retainer, record how many times it was turned to remove.
  9. Install new O-rings to the differential side retainers on both sides.
  10. Attach the differential side retainers to both sides.
    NOTE: When attaching, turn the side retainer the same number of turns it took to remove, and align the marks.
  11. Install the retainer lock plate.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb)

    NOTE: Be careful not to confuse the left and right side retainer lock plates.
    G13648233Courtesy of SUBARU OF AMERICA, INC.
  12. Remove any remaining liquid gasket from the clutch housing and adapter plate.
  13. Apply liquid gasket to the clutch housing.

    Liquid gasket: 

    THREE BOND 1215B or equivalent

    G05003353Courtesy of SUBARU OF AMERICA, INC.
  14. Install the drive pinion shaft assembly. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) (TY85)>DRIVE PINION SHAFT ASSEMBLY>INSTALLATION .
  15. Install the individual gear assemblies all at once. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) (TY85)>MAIN SHAFT ASSEMBLY>INSTALLATION .
  16. Install the transmission case. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) (TY85)>TRANSMISSION CASE>INSTALLATION .
  17. Install the center differential. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) (TY85)>CENTER DIFFERENTIAL>INSTALLATION .
  18. Install the transfer driven gear. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) (TY85)>TRANSFER DRIVEN GEAR>INSTALLATION .
  19. Install the extension case. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) (TY85)>EXTENSION CASE>INSTALLATION .
  20. Install the neutral position switch, back-up light switch and harness. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) (TY85)>NEUTRAL POSITION SWITCH>INSTALLATION . Refer to MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) (TY85)>BACK-UP LIGHT SWITCH>INSTALLATION .
  21. Install the manual transmission assembly to the vehicle. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL(6MT) (TY85)>MANUAL TRANSMISSION ASSEMBLY>INSTALLATION .
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