Subaru Legacy IV (2008 year). Service manual — part 882
DI-77
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.
ST1
18678AA000 DUMMY SHAFT
ST2
18831AA010 DIFFERENTIAL CARRIER
GAUGE
(2) Install the side retainer LH to the left side of
the differential carrier in the reverse direction.
(3) 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
18678AA000 DUMMY SHAFT
ST2
18831AA010 DIFFERENTIAL CARRIER
GAUGE
Preload adjusting washer
Part No.
Thickness mm (in)
38336AA430
1.500 (0.0591)
38336AA440
1.513 (0.0596)
38336AA450
1.525 (0.0600)
38336AA460
1.538 (0.0606)
38336AA470
1.550 (0.0610)
38336AA480
1.563 (0.0615)
38336AA490
1.575 (0.0620)
38336AA500
1.588 (0.0625)
38336AA510
1.600 (0.0630)
38336AA520
1.613 (0.0635)
38336AA530
1.625 (0.0640)
38336AA540
1.638 (0.0645)
38336AA550
1.650 (0.0650)
38336AA560
1.663 (0.0655)
38336AA570
1.675 (0.0659)
38336AA580
1.688 (0.0665)
38336AA590
1.700 (0.0669)
38336AA600
1.713 (0.0674)
38336AA610
1.725 (0.0679)
38336AA620
1.738 (0.0684)
38336AA630
1.750 (0.0689)
38336AA640
1.763 (0.0694)
38336AA650
1.775 (0.0699)
Preload adjusting spacer
Part No.
Length mm (in)
31454AA250
51.05 (2.010)
31454AA260
51.25 (2.018)
31454AA270
51.35 (2.022)
31454AA280
51.45 (2.026)
31454AA290
51.55 (2.030)
31454AA300
51.65 (2.033)
31454AA310
51.75 (2.037)
31454AA320
51.85 (2.041)
31454AA330
52.05 (2.049)
N Measured value
(A) Pinion height adjusting washer
RH
LH
N
(A)
ST2
ST1
DI-00379
DI-00380
DI-00381
ST2
ST1
DI-78
Rear Differential (VA-type)
DIFFERENTIALS
(4) 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 (0.002 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 32295AA370.
3) Install the selected pinion height adjusting wash-
er 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 bearing preload adjust-
ing spacer and washer.
5) Set ST and differential carrier to the press and
install the front bearing cone.
ST
399780104
WEIGHT
NOTE:
Set the carrier to the press until the companion
flange is installed.
6) Insert the spacer, then install the pilot bearing.
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)
32295AA350
0.150 (0.0059)
32295AA360
0.175 (0.0069)
32295AA370
0.200 (0.0079)
32295AA380
0.225 (0.0089)
32295AA390
0.250 (0.0098)
32295AA400
0.275 (0.0108)
ST
DI-00085
(A) Drive pinion
(B) Bearing preload adjusting spacer
(C) Bearing preload adjusting washer
(D) Differential carrier
(A) Pilot bearing
(B) Spacer
(D)
(A)
(B)
(C)
DI-00382
ST
DI-00383
DI-00389
(A)
(B)
DI-79
Rear Differential (VA-type)
DIFFERENTIALS
7) Fit a new oil seal with ST.
NOTE:
• Press-fit until the oil seal end comes 1 mm (0.04
in) inward from end of carrier.
• Apply the differential gear oil to the oil seal lips.
ST
499277200
INSTALLER
8) Press-fit the companion flange with ST.
NOTE:
Be careful not to damage the bearing.
ST
899874100
INSTALLER
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) Tighten the nut and use the ST to fix the com-
panion flange in place, then tighten.
ST
498427200
FLANGE WRENCH
Tightening torque:
191 N·m (19.5 kgf-m, 140.9 ft-lb)
11) Measure the initial torque and initial load.
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 — 0.90 ft-lb)
12) Install the hypoid driven gear to differential
case.
NOTE:
• Set a cushioning such as wooden block, alumi-
num plate or shop cloth between vise and differen-
tial case if the side gear comes into contact with
vise.
• Before installing bolts, apply seal material to bolt
threads.
SEAL MATERIAL:
THREE BOND 1324 (Part No. 004403042)
• Tighten diagonally.
Tightening torque:
62 N·m (6.3 kgf-m, 45.7 ft-lb)
ST
DI-00089
DI-00384
ST
DI-00372
ST
DI-00152
DI-00481
DI-00371
DI-80
Rear Differential (VA-type)
DIFFERENTIALS
13) Press the side bearing into differential case us-
ing ST.
ST
398487700
DRIFT
14) Assemble the side retainer.
(1) Attach the new oil seal to the side retainer
RH and LH.
ST
498447100
INSTALLER
(2) Attach the bearing race to side retainer RH
and LH.
ST
398417700
DRIFT
CAUTION:
Be careful to properly match the RH and LH oil
seals, bearing outer races and cones during as-
sembly.
(3) Install the differential assembly into differen-
tial carrier in the reverse order of disassembly.
NOTE:
Be careful not to hit the teeth against the case.
(4) Push the side retainer RH and LH lightly into
the differential carrier to install.
15) Perform the backlash adjustment between the
hypoid driven gear and drive pinion, and preload
adjustment of differential side bearing.
(1) Turn the drive pinion with ST for better fitting
of differential side bearing.
ST
498427200
FLANGE WRENCH
(2) Using the ST, tighten the side retainer LH,
and then tighten the side retainer RH until there
is no backlash.
ST
18630AA010
WRENCH COMPL
RETAINER
(3) Back off the side retainer LH by approx. 1.5
teeth, and tighten the side retainer RH by ap-
prox. 2 teeth (amount that the side retainer LH
is turned back (1.5) + 1/2 teeth).
Difference between [amount that the side re-
tainer LH is turned back (approx. 1 and 1/2
teeth)] and [amount that the side retainer RH is
tightened (approx. 2 teeth)] gives preload.
(4) Temporarily tighten the lock plate.
NOTE:
Turn over the lock plate to shift the holder by 0.5
teeth.
ST
DI-00095
ST
DI-00166
DI-00366
DI-00385
ST
ST
DI-00399
DI-00364
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