Subaru Legacy (2005 year). Service manual — part 736
DI-51
DIFFERENTIALS
Rear Differential (VA-type)
12) Drive out the pinion shaft lock pin from hypoid
driven gear side.
NOTE:
The lock pin is staked at the pin hole end on the dif-
ferential case. do not drive it out forcibly before
unstaking it.
ST
899904100
STRAIGHT PIN REMOVER
13) Draw out the pinion mate shaft and remove pin-
ion mate gears, side gears and thrust washers.
NOTE:
The gears should be marked or kept separated
right and left, and front and rear as well as thrust
washers.
14) Support the companion flange with ST and re-
move self-locking nut.
ST
498427200
FLANGE WRENCH
15) Extract the companion flange with a puller.
16) Press the end of drive pinion shaft and extract it
together with rear bearing cone, pinion height ad-
just washer and washer.
NOTE:
Hold the drive pinion so as not to drop it.
ST
398467700
DRIFT
17) 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
498515500
REPLACER
(A) Side gear
(B) Pinion mate gear
(C) Thrust washer
(D) Differential case
(E) Pinion mate shaft
DI-00237
ST
DI-00238
ST
DI-00141
(A) Companion flange
(B) Puller
(B)
(A)
DI-00142
ST
DI-00073
ST
DI-00074
DI-52
DIFFERENTIALS
Rear Differential (VA-type)
18) Remove the front oil seal from differential carri-
er using ST.
ST
398527700
PULLER ASSY
19) Remove the pilot bearing together with front
bearing cone and collar using ST.
ST
398467700
DRIFT
20) When replacing the bearings, hit out the front
bearing cup and rear bearing cup in this order by
using a brass bar.
2. VA2-TYPE
To detect the real cause of trouble, inspect the fol-
lowing items before disassembling.
• Tooth contact and backlash between hypoid driv-
en gear and drive pinion
• Hypoid driven gear runout on its back surface
• Total preload of drive pinion
1) Set the ST on vise and install the differential as-
sembly to ST.
ST
398217700
ATTACHMENT SET
2) Drain the gear oil by removing plug.
3) Remove the rear cover by loosening retaining
bolts.
4) Remove the lock plate RH and LH.
(A) Differential carrier
(B) Front oil seal
(A) Pilot bearing
(B) Collar
(C) Front bearing
(D) Rear bearing cup
(A) 2 cutouts along diagonal lines
(B) Hit out alternately with brass bar
(B)
(A)
DI-00145
ST
(B)
(A)
(C)
(D)
DI-00076
(B)
(A)
DI-00077
ST
DI-00363
DI-00388
DI-00364
DI-53
DIFFERENTIALS
Rear Differential (VA-type)
5) Remove the holder RH and LH with ST.
ST
18630AA010
WRENCH ASSY
6) Pull out the differential assembly from differential
carrier.
NOTE:
Be careful not to hit the teeth against the case.
7) Remove the bearing race from holder RH and
LH with ST1 and press.
ST
18758AA000
PULLER
NOTE:
• Make sure the bolt of puller turn manually.
• Set the puller so that its claws catch the groove of
holder.
8) Remove the oil seal from holder RH and LH us-
ing screwdriver.
NOTE:
Perform this operation only when replacing oil seal.
9) Extract the bearing cone with ST1, ST2 and
ST3.
NOTE:
• Do not attempt to disassemble the parts unless
necessary.
• Never mix up the bearing races RH and LH and
cones.
ST1
498077000
REMOVER
ST2
399520105
SEAT
ST
DI-00365
DI-00366
(A) Groove
(B) Claw
(A) Holder
ST
DI-00367
ST
(A)
(B)
(A)
ST
DI-00368
DI-00369
DI-54
DIFFERENTIALS
Rear Differential (VA-type)
ST3
899864100
REMOVER
10) Remove the hypoid driven gear by loosening
hypoid driven gear bolts.
11) Support the companion flange with ST and re-
move self-locking nut.
ST
498427200
FLANGE WRENCH
12) Extract the companion flange with a puller.
13) Removes the drive pinion shaft.
14) Remove the rear bearing cone from drive pin-
ion by supporting cone with ST.
NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST
398517700
REPLACER
15) Remove the front oil seal from differential carri-
er using screwdriver.
16) Remove the pilot bearing, front bearing cone
and collar.
17) When replacing the bearings, hit out the front
bearing cup and rear bearing cup in this order by
using a brass bar.
(A) Companion flange
(B) Puller
DI-00370
ST1
ST2
ST3
DI-00371
DI-00372
ST
(B)
(A)
DI-00394
(A) Pilot bearing
(B) Collar
(C) Front bearing
(D) Rear bearing cup
(A) 2 cutouts along diagonal lines
(B) Hit out alternately with brass bar
DI-00373
ST
(B)
(A)
(C)
(D)
DI-00374
(B)
(A)
DI-00077
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