Subaru Legacy IV (2008 year). Service manual — part 879
DI-65
Rear Differential (VA-type)
DIFFERENTIALS
11) Remove the hypoid driven gear by loosening
hypoid driven gear bolts.
12) Remove the self-locking nut while holding the
companion flange with ST.
ST
498427200
FLANGE WRENCH
13) Extract the companion flange with a puller.
14) Removes the drive pinion shaft.
15) Remove the rear bearing cone from drive pin-
ion by supporting the cone with ST.
NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST
398517700
REPLACER
16) Remove the front oil seal from differential carri-
er using screwdriver.
17) Remove the pilot bearing, front bearing cone
and spacer.
18) When replacing the bearings, hit out the front
bearing cup and rear bearing cup in this order using
a brass bar.
(A) Companion flange
(B) Puller
DI-00371
DI-00372
ST
(B)
(A)
DI-00394
(A) Pilot bearing
(B) Spacer
(C) Front bearing
(D) Rear bearing cup
(A) 2 cutout portions along diagonal lines
(B) Tap alternately with brass bar.
DI-00373
ST
(B)
(A)
(C)
(D)
DI-00374
(B)
(A)
DI-00077
DI-66
Rear Differential (VA-type)
DIFFERENTIALS
D: ASSEMBLY
1. VA1-TYPE
NOTE:
• Assemble in the reverse order of disassembly.
• Check and adjust each part during assembly.
• Use new gaskets and O-rings.
• Keep the shims and washers in order, so that
they are not improperly installed.
• Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
• Apply gear oil when installing the bearings and
thrust washers.
• Be careful not to mix up the RH and LH bearing
races.
• Replace the oil seals and O-rings with new parts
at every disassembly.
• Apply differential gear oil to the lips when install-
ing the oil seal.
• Be careful not to mix up the differential oil seal
RH and LH.
1) Adjusting preload for front and rear bearings
NOTE:
Adjust the bearing preload between front and rear
bearings with spacer and washer. Pinion height ad-
justing washer is not affected by this adjustment.
The adjustment must not be carried out with oil seal
inserted.
(1) Install the rear bearing race into the differen-
tial carrier using ST1 and ST2.
ST1
398477701
HANDLE
ST2
398477702
DRIFT
(2) Install the front bearing race to the differen-
tial carrier using ST1 and ST2.
ST1
398477701
HANDLE
ST2
498447110
DRIFT
(3) Insert the front bearing cone.
NOTE:
Use new front bearing cone.
(4) Measure and record the thickness of pinion
height adjusting washer.
NOTE:
If tooth contact (drive pinion and hypoid driven
gear) is normal in the inspection before disassem-
bling, verify that the washer is not deformed, and
then reuse the used washer.
(5) Insert ST1 into the case with the pinion
height adjusting washer and rear bearing cone
fitted onto it.
NOTE:
Use new rear bearing cone.
(6) Install the preload adjusting spacer & wash-
er, front bearing cone, ST2, companion flange,
and washer & self-locking nut.
ST
498447150
DUMMY SHAFT
Part No. 32285AA000 Spacer
DI-00078
DI-00149
ST2
ST1
(A) Pinion height adjusting washer
(B) Preload adjusting spacer
(C) Preload adjusting washer
(D) Spacer (SUBARU genuine part)
DI-00466
(B)
(A)
(C)
ST
(D)
DI-67
Rear Differential (VA-type)
DIFFERENTIALS
(7) Turn the ST1 by hand to smooth the bear-
ing, and tighten the self-locking nut while mea-
suring the initial load or initial torque with a
spring scale or torque wrench. Select the pre-
load adjusting washer and spacer so that the
specified preload is obtained when nut is tight-
ened to the specified torque.
NOTE:
• Use a new self-locking nut.
• Measure the preload in direction of tangent to the
flange.
• Be careful not to give excessive preload.
• When tightening the self-locking nut, lock ST1
with ST2 as shown in the figure.
ST1
498447150
DUMMY SHAFT
ST2
398507704
BLOCK
Tightening torque:
191 N·m (19.5 kgf-m, 140.9 ft-lb)
Initial load:
12.7 — 32.2 N (1.3 — 3.3 kgf, 2.9 — 7.2 lb)
Initial torque:
0.48 — 1.22 N·m
(0.05 — 0.12 kgf-m, 0.35 — 0.9 ft-lb)
ST1
ST2
DI-00081
DI-00152
DI-00481
Preload adjusting washer
Part No.
Thickness mm (in)
38336AA000
1.500 (0.0591)
38336AA120
1.513 (0.0596)
38336AA010
1.525 (0.0600)
38336AA130
1.538 (0.0606)
38336AA020
1.550 (0.0610)
38336AA140
1.563 (0.0615)
38336AA030
1.575 (0.0620)
38336AA150
1.588 (0.0625)
38336AA040
1.600 (0.0630)
38336AA160
1.613 (0.0635)
38336AA050
1.625 (0.0640)
38336AA170
1.638 (0.0645)
38336AA060
1.650 (0.0650)
38336AA180
1.663 (0.0655)
38336AA070
1.675 (0.0659)
38336AA190
1.688 (0.0665)
38336AA080
1.700 (0.0669)
38336AA200
1.713 (0.0674)
38336AA090
1.725 (0.0679)
38336AA210
1.738 (0.0684)
38336AA100
1.750 (0.0689)
38336AA220
1.763 (0.0694)
38336AA110
1.775 (0.0699)
Preload adjusting spacer
Part No.
Length mm (in)
32288AA040
52.3 (2.059)
32288AA050
52.5 (2.067)
31454AA100
52.6 (2.071)
32288AA060
52.7 (2.075)
31454AA110
52.8 (2.079)
32288AA070
52.9 (2.083)
31454AA120
53.0 (2.087)
32288AA080
53.1 (2.091)
32288AA090
53.3 (2.098)
DI-68
Rear Differential (VA-type)
DIFFERENTIALS
2) Adjusting drive pinion height:
Adjust the drive pinion height with washer installed
between the rear bearing cone and the back of pin-
ion gear.
(1) Attach ST2.
NOTE:
At this time, install a provisionally selected or previ-
ously used pinion height adjusting washer.
ST1
498447150
DUMMY SHAFT
ST2
498505501
DIFFERENTIAL CARRIER
GAUGE
Part No.
32285AA000 Spacer
(2) Measure the clearance “N” between the end
of ST2 and the end surface of ST1 by using a
thickness gauge.
NOTE:
Make sure there is no clearance between the case
and ST2.
ST1
498447150
DUMMY SHAFT
ST2
498505501
DIFFERENTIAL CARRIER
GAUGE
(3) Obtain the thickness of pinion height adjust-
ing washer to be inserted from the following for-
mula, and replace the temporarily installed
washer with this one.
NOTE:
Adjust it using 1 — 3 washers.
T = To + N – 0.05 mm (0.0020 in)
(Example of calculation)
To = 0.15 mm (0.0059 in)
N = 0.1 mm (0.0039 in)
T = 0.15 mm (0.0059 in) + 0.1 mm (0.0039 in) –
0.05 mm (0.0020 in) = 0.2 mm (0.0079 in)
Result: Thickness = 0.2 mm (0.0079 in)
Therefore use part number 32295AA220.
3) Install the selected pinion height adjusting wash-
er on drive pinion, and press the rear bearing cone
into position with ST.
ST
498175500
INSTALLER
N Measured value
(A) Pinion height adjusting washer
(B) Spacer (SUBARU genuine part)
DI-00467
RH
LH
N
(A)
ST2
ST1
(B)
ST2
ST1
DI-00084
T
Thickness of pinion height adjusting
washer mm (in)
To
Thickness of washer temporarily
inserted mm (in)
N
Clearance of thickness gauge mm (in)
Memo:
Pinion height adjusting washer
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)
ST
DI-00085
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