Subaru Legacy III (2000-2003 year). Service manual — part 674
DI-50
DIFFERENTIALS
REAR DIFFERENTIAL FOR VA-TYPE
(3) Obtain the thickness of pinion height adjust-
ing washer to be inserted from the following for-
mula, and replace the temporarily installed shim
with this one.
NOTE:
Use 1 to 3 shims as required for adjustment.
T = To + N
−
0.05 (mm)
where
T = Thickness of pinion height adjusting shim
(mm)
To = Thickness of shim originally installed
(mm)
N = Reading of thickness gauge (mm)
H = Figure marked on drive pinion head
(Example of calculation)
To = 0.15 mm
N = 0.1 mm
T = 0.15 + 0.1
−
0.05 = 0.2 mm
Result: Thickness = 0.2 mm
Therefore use the 32295AA220.
3) Install the selected pinion height adjusting shim
on drive pinion, and press the rear bearing cone
into position with ST.
ST
498175500
INSTALLER
4) Insert drive pinion into differential carrier, install
the previously selected bearing preload adjusting
spacer and washer.
5) Press-fit front bearing cone into carrier with ST1,
ST2 and ST3.
ST1
32285AA000 DUMMY COLLAR
ST2
399780104
WEIGHT
ST3
899580100
INSTALLER
6) Insert spacer, then press-fit pilot bearing with
ST1 and ST2.
ST1
399780104
WEIGHT
ST2
899580100
INSTALLER
Pinion height adjusting shim
Part No.
Thickness mm (in)
32295AA200
0.150 (0.0059)
32295AA210
0.175 (0.0069)
32295AA220
0.200 (0.0079)
32295AA230
0.225 (0.0089)
32295AA240
0.250 (0.0098)
32295AA250
0.275 (0.0108)
DI-00085
ST
(A) Drive pinion
(B) Bearing preload adjusting spacer
(C) Bearing preload adjusting washer
(D) Differential carrier
DI-00086
( D )
( C )
( B )
( A )
DI-00087
ST2
ST1
ST3
DI-00088
ST2
ST1
DI-51
DIFFERENTIALS
REAR DIFFERENTIAL FOR VA-TYPE
7) Fit a new oil seal with ST.
NOTE:
• Press-fit until end of oil seal is 1 mm (0.04 in) in-
ward from end of carrier.
• Apply grease between the oil seal lips.
ST
498447120
OIL SEAL INSTALLER
8) Press-fit companion flange with ST1 and ST2.
NOTE:
Be careful not to damage bearing.
ST1
899874100
INSTALLER
ST2
399780104
WEIGHT
9) Install self-locking nut. Then tighten it with ST.
ST
398427200
FLANGE WRENCH
Tightening torque:
188 N·m (19.2 kgf-m, 139 ft-lb)
10) Assembling differential case
Install side gears and pinion mate gears, with their
thrust washers and pinion mate shaft, into differen-
tial case.
NOTE:
• Apply gear oil on both sides of the washer and on
the side gear shaft before installing.
• Insert the pinion mate shaft into the differential
case by aligning the lock pin holes.
(1) Measure the side gear backlash.
Side gear back clearance:
0.05 — 0.15 mm (0.0020 — 0.0059 in)
(2) Adjust the side gear backlash as specified
by selecting side gear thrust washer.
(3) Check the condition of rotation after apply-
ing oil to the gear tooth surfaces and thrust sur-
faces.
ST
DI-00089
DI-00090
ST1
ST2
DI-00161
ST
Side gear thrust washer
Part No.
Thickness mm (in)
803135011
0.925 — 0.950 (0.0364 — 0.0374)
803135012
0.950 — 0.975 (0.0374 — 0.0384)
803135013
0.975 — 1.000 (0.0384 — 0.0394)
803135014
1.000 — 1.025 (0.0394 — 0.0404)
803135015
1.025 — 1.050 (0.0404 — 0.0413)
DI-00239
DI-00240
DI-52
DIFFERENTIALS
REAR DIFFERENTIAL FOR VA-TYPE
(4) After driving in pinion shaft lock pin, stake
the both sides of the hole to prevent pin from fall-
ing off.
(5) Install crown gear on differential case.
NOTE:
• Before installing bolts, apply Lock Tite to bolt
threads.
Lock Tite
THREE BOND 1324 (Part No.: 004403042)
or equivalent
• Tighten diagonally while tapping the bolt heads.
Tightening torque:
62 N·m (6.3 kgf-m, 45.6 ft-lb)
11) Press side bearing cone onto differential case
with ST.
ST
498485400
DRIFT
12) Assemble holders.
(1) Install oil seal into right and left holders.
ST
498447100
AXLE SHAFT OIL SEAL IN-
STALLER
(2) Install bearing race into right and left hold-
ers.
ST
398477702
BEARING OUTER RACE
DRIFT
(3) Install the differential case assembly into dif-
ferential carrier in the reverse order of disas-
sembly.
(4) Lightly screw-in side holders of RH an LH
into differential carrier and install.
13) Perform adjustment of backlash of pinion
crown gear set and adjustment of preload of differ-
ential side bearing.
(1) Turn drive pinion with ST for better fitting of
differential side bearing.
ST
498427200
FLANGE WRENCH
DI-00068
ST
DI-00095
DI-00166
ST
ST
DI-00167
DI-00134
ST
DI-00169
DI-53
DIFFERENTIALS
REAR DIFFERENTIAL FOR VA-TYPE
(2) Screw in side (left-side) holder until light
contact is made with ST.
ST
399780111
WRENCH
(3) Back off side (left-side) holder approximate-
ly 1 1/2 teeth of holder, and tighten left-side
holder by approximately 2 teeth (approximately
1 1/2 + 1/2 teeth).
[Back off amount of side (left-side) holder + 1/2
tooth.]
This + 1/2 tooth gives preload.
(4) Temporarily tighten lock plate.
NOTE:
Turn over lock plate to displace holder 1/2 tooth.
(5) Measure the crown gear-to-drive pinion
backlash. Set magnet base on differential carri-
er. Align contact point of dial gauge with tooth
face of crown gear, and move crown gear while
holding drive pinion still. Read value indicated
on dial gauge.
NOTE:
If measured backlash is not within specified range,
repeat procedures for pinion crown gear set back-
lash adjustment and differential side bearing pre-
load adjustment.
Backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
14) Draw a matching mark on both differential car-
rier and holder. Remove holder one side at a time.
Replace in the original position after inserting an O-
ring and applying grease to threaded portion.
15) Tighten bolt of lock plate to specified torque.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
DI-00133
ST
DI-00132
(A) Matching mark
(B) Holder
DI-00172
DI-00173
( A )
( B )
DI-00132
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