A: REMOVAL
1) Shift the select lever or gear shift lever to neutral.
2) Release the parking brake.
3) Disconnect the ground cable from battery.
4) Loosen the wheel nuts.
5) Lift up the vehicle.
6) Remove the rear wheels.
7) Drain differential gear oil. <Ref. to DI-23, REPLACEMENT, Differential Gear Oil.>
8) Remove the rear exhaust pipe.
9) Remove the heat shield cover.
10) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.>
11) Loosen the self-lock nuts which hold the rear differential to rear crossmember.
12) Remove the DOJ of rear drive shaft from rear differential using ST or tire lever.
NOTE:
T-type
ST 28099PA100 DRIVE SHAFT REMOVER
VA-type
13) Set the rear differential to transmission jack.
14) Remove the mass damper. (CVT model)
15) Remove the rear differential front member.
16) Remove the self-locking nuts which hold the rear differential to the crossmember.
17) Pull out the rear differential stud bolt from rear crossmember bushing.
NOTE: When removing the stud bolt from the rear crossmember bushing, carefully adjust the angle and location of transmission jack and jack stand, if necessary.
18) Lower the transmission jack.
19) Pull out the rear drive shaft from the rear differential.
NOTE:
ST 28099PA100 DRIVE SHAFT REMOVER
20) Lower the transmission jack.
21) Secure the rear drive shaft to rear lateral link using wire.
22) Remove the rear differential member plate from rear differential.
B: INSTALLATION
1) Attach the rear differential member plate to the rear differential.
2) Set the rear differential to transmission jack.
3) Set the ST to the rear differential.
ST 28099PA090 OIL SEAL PROTECTOR
4) Insert the rear drive shaft until the spline portion of the rear drive shaft exceeds the side oil seal.
5) Remove ST from rear differential.
6) Push the rear differential from side to side to insert the DOJ into rear differential completely.
7) Adjust the transmission jack, if necessary, and insert the rear differential stud bolt into rear crossmember bushing properly.
8) After inserting the rear differential stud bolt into the rear crossmember bushing, lift up the transmission jack and align the rear differential to its attachment position.
9) Tighten a new self-locking nut temporarily to rear crossmember.
10) Install the rear differential front member with a new self-locking nut.
Tightening torque:
T1: 50 N*m (5.1 kgf-m, 36.9 ft-lb)
T2: 110 N*m (11.2 kgf-m, 81.1 ft-lb)
11) Install the mass damper with a new self-locking nut. (CVT model)
Tightening torque: 50 N*m (5.1 kgf-m, 36.9 ft-lb)
12) Remove the transmission jack.
13) Tighten the self-locking nut.
NOTE: For models other than OUTBACK model, tighten the self-locking nut using the ST.
ST 41399YC000 SOCKET WRENCH (17)
Tightening torque: 70 N*m (7.1 kgf-m, 51.6 ft-lb)
14) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.>
15) Install the heat shield cover.
Tightening torque: 18 N*m (1.8 kgf-m, 13.3 ft-lb)
16) Install the rear exhaust pipe.
17) Fill differential gear oil. <Ref. to DI-23, REPLACEMENT, Differential Gear Oil.>
18) Installing procedure hereafter is in the reverse order of removal.
19) Perform "Rear differential inspection mode " using the Subaru Select Monitor. (CVT model) <Ref. to DI-84, Rear Differential Inspection Mode.>
CAUTION: Be sure to perform rear differential inspection mode when the following work has been performed.
C: DISASSEMBLY
To detect the real cause of trouble, inspect the following items before disassembling.
1) Set the ST on vise and install the differential assembly to ST.
ST 398217700 ATTACHMENT SET
2) Remove the drain plug and filler plug.
3) Remove the air breather cap.
NOTE:
4) Remove the bolts, and then remove the rear cover.
5) Remove the side retainer attachment bolts, set the ST to differential case, and extract the side retainers RH and LH with a puller.
NOTE:
ST 398457700 ATTACHMENT
6) Remove the oil seal from the side retainer.
7) Pull out the differential case assembly from the differential carrier.
NOTE: Be careful not to hit the teeth of hypoid driven gear against the differential carrier.
8) When replacing the side bearing, remove the bearing race from the side retainer using ST.
ST 398527700 PULLER ASSY
9) Using the ST, remove the bearing cone.
NOTE:
ST 18759AA000 PULLER ASSY
10) Remove the hypoid driven gear by loosening hypoid driven gear bolts.
11) Remove the pinion shaft lock pin from hypoid driven gear side using ST.
ST 899904100 STRAIGHT PIN REMOVER
12) Draw out the pinion mate shaft, and remove pinion mate gears, pinion mate gear washers, side gears, and thrust washers.
NOTE: The gears and washers should be marked with RH or LH, front or rear, or kept separately.
13) Remove the self-locking nut while securing the companion flange with ST.
ST 498427200 FLANGE WRENCH
14) Extract the companion flange with a puller.
15) Press the end of drive pinion shaft using ST and remove the rear bearing cone, preload adjusting spacer and washer.
NOTE: Hold the drive pinion so as not to drop it.
ST 398467700 DRIFT
16) Remove the rear bearing cone from drive pinion by supporting the cone with ST.
NOTE: Place the replacer so that its center-recessed side faces the bearing cone.
ST 398517700 REPLACER
17) Remove the front oil seal from differential carrier using ST.
ST 398527700 PULLER ASSY
18) Remove the pilot bearing together with the front bearing cone and spacer using the ST.
ST 398467700 DRIFT
19) When replacing the bearings, use a brass bar to tap out the front bearing race and rear bearing race in this order to remove them.
D: ASSEMBLY
NOTE:
1) Adjusting preload for front and rear bearings NOTE: Adjust the bearing preload between front and rear bearings with preload adjusting spacer and washer.
Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted.
ST1 398477701 HANDLE
ST2 398477703 DRIFT 2
ST1 398477701 HANDLE
ST2 398477702 DRIFT
NOTE:
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
NOTE:
ST1 398507702 DUMMY SHAFT
ST2 398507704 BLOCK
Tightening torque: 181.5 N*m (18.5 kgf-m, 133.9 ft-lb)
Initial load: 18.1 - 38.8 N (1.8 - 4.0 kgf, 4.1 - 8.7 lbf)
Initial torque: 0.69 - 1.47 N*m (0.07 - 0.15 kgf-m, 0.51 - 1.08 ft-lb)
2) Adjusting drive pinion height: Adjust the drive pinion height with pinion height adjusting washer installed between the rear bearing cone and the back of pinion gear.
NOTE: At this time, install a provisionally selected or previously used pinion height adjusting washer. Measure and record the thickness.
ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER
GAUGE
ST3 398507703 DUMMY COLLAR
NOTE: Make sure there is no clearance between the differential carrier and ST2.
ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER
GAUGE
T = To + N - (H × 0.01) - 0.20 mm (0.0079 in)
(Example of calculation)
To = 3.39 mm (0.1335 in)
N = 0.24 mm (0.0094 in)
H = + 1
T = 3.39 mm (0.1335 in) + 0.24 mm (0.0094 in)
- 0.01 mm (0.0004 in) - 0.20 mm (0.0079 in) = 3.42 mm (0.1346 in)
Result: Thickness = 3.42 mm (0.1346 in)
Therefore use washer 383605200.
3) Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST.
ST 398177700 INSTALLER
4) Insert the drive pinion into the differential carrier, and install the preselected preload adjusting spacer and washer.
5) Press-fit the front bearing cone with ST1, ST2 and ST3.
ST1 398507703 DUMMY COLLAR
ST2 399780104 WEIGHT
ST3 899580100 INSTALLER
6) Insert the spacer, then press-fit the pilot bearing with ST1 and ST2.
ST1 399780104 WEIGHT
ST2 899580100 INSTALLER
7) Using the ST, install the oil seal.
NOTE:
ST 498447120 INSTALLER
8) Press-fit the companion flange with ST1 and ST2.
NOTE: Be careful not to damage the bearing.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT
9) Apply seal material on the drive pinion shaft thread and new self-locking nut seat.
Seal material: THREE BOND 1324 (Part No. 004403042) or equivalent
10) Attach the new self-locking nut and use the ST to fix the companion flange in place, then tighten the self-locking nut.
Tightening torque: 181.5 N*m (18.5 kgf-m, 133.9 ft-lb)
ST 498427200 FLANGE WRENCH
11) Check the initial torque or initial load.
Initial load: 18.1 - 38.8 N (1.8 - 4.0 kgf, 4.1 - 8.7 lbf)
Initial torque: 0.69 - 1.47 N*m (0.07 - 0.15 kgf-m, 0.51 - 1.08 ft-lb)
12) Assembling differential case
Install the side gears and pinion mate gears, with their side gear thrust washers, pinion mate gear washer, and pinion mate shaft, into the differential case.
NOTE:
Side gear backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
13) Install the driven gear to the differential case.
NOTE:
Seal material: THREE BOND 1324 (Part No. 004403042) or equivalent
Tightening torque: 103 N*m (10.5 kgf-m, 76.0 ft-lb)
14) Using the ST, press-fit the side bearing to the differential case.
ST 398487700 DRIFT
15) Using the ST, press-fit the side bearing outer race to the side retainer.
CAUTION: Make sure that the bearing outer races and cones are properly assembled.
ST 398417700 DRIFT
16) Side retainer shim adjustment
NOTE: Be careful not to hit the teeth of hypoid driven gear against the differential carrier.
NOTE:
NOTE: Be careful that the side bearing outer race is not damaged by the bearing roller.
Tightening torque: 10.5 N*m (1.1 kgf-m, 7.7 ft-lb)
Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
If the total preload is outside the specification range, adjust the thickness of side retainer shims, increasing/reducing both shims by an even amount at a time.
Total preload: 20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7 - 12.2 lbf)
17) Recheck the hypoid driven gear to drive pinion backlash.
Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
18) Check pinion and hypoid driven gears rotate smoothly and make sure of the hypoid driven gear runout on its back surface. If the hypoid driven gear runout on its back surface exceeds the specification, check for any foreign objects between the hypoid driven gear and differential case, and for any deformation of the differential case or hypoid driven gear.
Hypoid driven gear back surface runout: 0.05 mm (0.002 in)
19) Check and adjustment of the tooth contact of hypoid driven gear and drive pinion
NOTE: Be sure to wipe off the lead-free red dye completely after the adjustment is completed.
Check item: Tooth contact pattern is slightly shifted toward toe side under no-load rotation.
(When driving, it moves towards the heel side.)
Check item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.
Check item: Backlash is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.
20) If proper tooth contact is not obtained, readjust the drive pinion height by changing the RH and LH side retainer shims and the hypoid gear backlash.
ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER
GAUGE
T = To + N - (H × 0.01) - 0.20 mm (0.0079 in)
Backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
21) Remove the RH and LH side retainers.
22) Install the O-ring to left and right side retainers.
NOTE: Use new O-rings.
23) Install the oil seal to the side retainer of both sides. <Ref. to DI-78, REPLACEMENT, Rear Differential Side Oil Seal.>
24) Align the arrow mark on the differential carrier with the arrow mark on the side retainer when installing the side retainer.
25) Apply liquid gasket to the bolts indicated by arrows, and tighten the bolts.
Liquid gasket: THREE BOND 1110B (Part No. K0879Y0020) or equivalent
Tightening torque: 10.5 N*m (1.1 kgf-m, 7.7 ft-lb)
26) Install the gasket and rear cover, and tighten the bolts to specified torque.
NOTE: Use a new gasket.
Tightening torque: 29.5 N*m (3.0 kgf-m, 21.8 ft-lb)
27) Install the air breather cap.
NOTE: When installing the air breather cap, do not tap section (A). Be sure to tap section (B) to install.
28) Install the drain plug.
NOTE: Apply liquid gasket to the drain plug.
Liquid gasket: THREE BOND 1105 (Part No. 004403010) or equivalent
Tightening torque: 49 N*m (5.0 kgf-m, 36.1 ft-lb)
29) Install the filler plug.
NOTE: After installing the rear differential assembly to the vehicle, fill the gear oil, then apply liquid gasket, and tighten to the specified torque. <Ref. to DI-23, REPLACEMENT, Differential Gear Oil.>
E: INSPECTION
Wash all the disassembled parts clean, and examine them for wear, damage and other defects. Repair or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
2) Side gear and pinion mate gear
3) Bearing
4) Thrust washer of the side gear and pinion mate gear
5) Oil seal
6) Differential carrier
7) Differential case
8) Companion flange
1. SIDE GEAR BACKLASH
Using a dial gauge, check the backlash of side gear.
Side gear backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
If the side gear backlash is not within the specification, select the side gear thrust washer and adjust the side gear backlash as specified.
2. HYPOID DRIVEN GEAR BACKLASH
Using a dial gauge, check the backlash of hypoid driven gear.
Hypoid driven gear backlash: 0.10 - 0.20 mm (0.004 - 0.008 in)
If the hypoid driven gear backlash is outside the specification range, adjust the side bearing preload and repair if necessary.
3. HYPOID DRIVEN GEAR RUNOUT ON ITS BACK SURFACE
Using a dial gauge, check the hypoid driven gear back surface runout.
Hypoid driven gear back surface runout: 0.05 mm (0.002 in)
If the hypoid driven gear runout on its back surface exceeds the limit, replace the hypoid driven gear.
4. TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between the hypoid driven gear and drive pinion. <Ref. to DI-32, ASSEMBLY, Rear Differential (T-type).>
5. TOTAL PRELOAD
Using a spring scale, check the total preload.
Total preload: 20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7 - 12.2 lb)
If the total preload is not within the specification, adjust the side retainer shim.
6. COMPANION FLANGE
1) If rust or dirt is attached to the companion flange, remove them.
2) Set a dial gauge at a companion flange surface (mating surface of propeller shaft and companion flange), and then measure the companion flange runout.
Limit of runout: 0.08 mm (0.003 in)
3) Set the gauge inside of the companion flange, and measure the runout.
Limit of runout: 0.08 mm (0.003 in)
4) If either runout exceeds the limit, move the phase of companion flange and drive pinion 90º each, and find the point where the runout is within the limit.
5) If the runout exceeds the limit even after changing the phase, replace the companion flange and recheck the runout.
6) If the runout exceeds the limit after replacing the companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.
F: ADJUSTMENT
1. SIDE GEAR BACKLASH
Adjust the side gear backlash. <Ref. to DI-32, ASSEMBLY, Rear Differential (T-type).>
2. HYPOID DRIVEN GEAR BACKLASH
Adjust hypoid driven gear backlash. <Ref. to DI-32, ASSEMBLY, Rear Differential (T-type).>
3. TOOTH CONTACT BETWEEN HYPOID DRIVEN GEAR AND DRIVE PINION
Adjust the tooth contact between hypoid driven gear and drive pinion gear. <Ref. to DI-32, ASSEMBLY, Rear Differential (T-type).>
4. TOTAL PRELOAD
Adjust the side retainer shim. <Ref. to DI-32, ASSEMBLY, Rear Differential (T-type).>