Subaru Legacy (2005 year). Service manual — part 660
5MT-87
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
5) Install the hypoid driven gear to differential case
using twelve bolts.
Tightening torque:
T: 62 N
⋅
m (6.3 kgf-m, 45.6 ft-lb)
2. SIDE RETAINER
1) Install a new oil seal.
ST
18675AA000
DIFFERENTIAL SIDE OIL
SEAL INSTALLER
NOTE:
• For press-fitting of oil seal to retainer, make tap-
ping with plastic hammer etc.
• Do not use press.
2) Install a new O-ring.
NOTE:
Do not stretch or damage the O-ring.
E: INSPECTION
Repair or replace the differential gear in following
cases:
• When the hypoid drive gear and drive pinion
shaft tooth surface are damaged, excessively worn
or seized.
• When the roller bearing on the drive pinion shaft
is worn or damaged.
• When there is damage, wear or seizure of the dif-
ferential bevel pinion, differential bevel gear, wash-
er, pinion shaft and straight pin.
• When the differential case sliding surfaces is
worn or damaged.
(A) Hypoid driven gear
(B) Differential case
MT-00993
(B)
(A)
T
MT-00289
ST
MT-00279
(A) Drive pinion shaft
(B) Hypoid driven gear
(C) Pinion shaft
(D) Straight pin
(E) Washer
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Roller bearing
(I) Differential case
MT-00291
(A)
(B)
(C)
(E)
(E)
(F)
(F)
(G)
(G)
(D)
(H)
(I)
(H)
5MT-88
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
1. BEVEL PINION GEAR BACKLASH
Measure the backlash between bevel gear and pin-
ion. If it is not within specification, install a suitable
washer to adjust.
NOTE:
Be sure the pinion gear teeth contacts adjacent
gear teeth during measurement.
ST1
498247001
MAGNET BASE
ST2
498247100
DIAL GAUGE
Standard backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
2. HYPOID GEAR BACKLASH
1) Set the ST1, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface on
the right corner and check the backlash.
ST1
498247001
MAGNET BASE
ST2
498247100
DIAL GAUGE
ST3
498255400
PLATE
2) Install the SUBARU genuine axle shafts to both
side, rotate in the inversion direction so that the
gauge contact with the tooth surface and read the
dial gauge.
Part No. 38415AA100AXLE SHAFT
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
NOTE:
If the backlash is outside the specified range, ad-
just it by turning the side retainer in right side case.
3. TOOTH CONTACT OF HYPOID GEAR
Check tooth contact of hypoid gear as follows: Ap-
ply a uniform thin coat of red lead on both tooth sur-
faces of 3 or 4 teeth of the hypoid gear. Move the
hypoid gear back and forth by turning the transmis-
sion main shaft until a definite contact pattern is de-
veloped on hypoid gear, and judge whether face
contact is correct. If it is inaccurate, make adjust-
ment. <Ref. to 5MT-88, ADJUSTMENT, Front Dif-
ferential Assembly.>
• Tooth contact is correct.
F: ADJUSTMENT
1. BEVEL PINION GEAR BACKLASH
1) Disassemble the front differential. <Ref. to 5MT-
84, REMOVAL, Front Differential Assembly.>
2) Select a different washer from the table and in-
stall.
3) Adjust until the standard is obtained.
Backlash:
Standard
0.13 — 0.18 mm (0.0051 — 0.0071 in)
MT-00285
ST1
ST2
MT-00293
ST1
ST2
ST3
(A) Toe
(B) Coast side
(C) Heel
(D) Drive side
Washer
Part Number
Thickness mm (in)
803038021
0.925 — 0.950
(0.0364 — 0.0374)
803038022
0.975 — 1.000
(0.0384 — 0.0394)
803038023
1.025 — 1.050
(0.0404 — 0.0413)
MT-00294
(A)
(B)
(C)
(D)
5MT-89
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
2. HYPOID GEAR BACKLASH
Adjust the backlash by turning holder in the right
side case.
ST
499787000
WRENCH ASSY
NOTE:
Each time the side retainer rotates one notch,
backlash changes by 0.05 mm (0.020 in).
3. TOOTH CONTACT OF HYPOID GEAR
1) Adjust until correct teeth contact is obtained.
2) Check tooth contact as follows.
• Tooth contact
Checking item: Tooth contact pattern is slightly
shifted to toe side under no-load rotation.
[When loaded, contact pattern moves toward
heel.]
• Face contact
Checking item: Backlash is too large.
Contact pattern
Corrective action: Reduce thickness of pinion
height adjusting washer in order to bring drive pin-
ion closer to driven gear.
• Flank contact
Checking item: Backlash is too small.
Contact pattern
Corrective action: Increase thickness of pinion
height adjusting washer in order to bring drive pin-
ion away from driven gear.
(A) Toe side
(B) Heel side
MT-00176
ST
MT-00296
0.05mm(0.0020 in)
AT-00207
(A)
(B)
AT-00208
AT-00212
AT-00209
AT-00213
5MT-90
MANUAL TRANSMISSION AND DIFFERENTIAL
Front Differential Assembly
• Toe contact (inside end contact)
Checking item: Contact area is small.
Contact pattern
Corrective action: Increase thickness of pinion
height adjusting washer in order to bring drive pin-
ion closer to driven gear.
• Heel contact (outside end contact)
Checking item: Contact area is small.
Contact pattern
Corrective action: Reduce thickness of pinion
height adjusting washer in order to bring drive pin-
ion away from driven gear.
AT-00210
AT-00213
AT-00211
AT-00212
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