Subaru Legacy (2005 year). Service manual — part 739
DI-63
DIFFERENTIALS
Rear Differential (VA-type)
1) Adjusting preload for front and rear bearings:
Adjust the bearing preload with collar and washer
between front and rear bearings. Pinion height ad-
justing washer are not affected by this adjustment.
The adjustment must be carried out without oil seal
inserted.
(1) Install the rear bearing race into differential
carrier with ST1 and ST2.
ST1
398477701
HANDLE
ST2
398477703
DRIFT 2
(2) Using the ST, install the front bearing race to
the differential carrier.
ST
499277200
INSTALLER
(3) Insert the front bearing cone.
NOTE:
Use new front bearing cone.
(4) Measure and record the thickness of pinion
adjust washer.
NOTE:
If tooth contact (drive pinion, hypoid driven gear) is
normal in the inspection before disassembling, ver-
ify that the washer is not deformed, and then re-use
the used washer.
(5) Insert the ST1 into carrier with pinion height
adjusting washer and rear bearing cone fitted
onto it.
NOTE:
Use new rear bearing cone.
(6) Install the preload adjusting collar and
washer, front bearing cone, collar, companion
flange, and washer and self-locking nut.
ST1
18678AA000 DUMMY SHAFT
(7) Turn the ST1 with hand to make it seated,
and tighten the self-locking nut while measuring
the preload with spring balance. Select the pre-
load adjusting washer and collar so that the
specified preload is obtained when nut is tight-
ened to the specified torque.
NOTE:
• Use a new self-locking nut.
• Be careful not to give excessive preload.
• When tightening the self-locking nut, lock com-
panion flange using ST2 as shown in the figure.
• Measure the preload in direction of tangent to
flange.
ST1
18678AA000 DUMMY SHAFT
ST2
498427200
FLANGE WRENCH
DI-00375
ST2
ST1
DI-00376
ST
(A) Pinion height adjusting washer
(B) Preload adjusting collar
(C) Preload adjusting washer
(D) Collar
ST1
DI-00377
(D)
(C)
(B)
(A)
DI-00152
DI-64
DIFFERENTIALS
Rear Differential (VA-type)
Tightening torque:
191 N
⋅
m (19.5 kgf-m, 141 ft-lb)
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) Install the ST2.
ST1
18678AA000 DUMMY SHAFT
ST2
18831AA010 DIFFERENTIAL CARRIER
GAUGE
(2) Install the side holder LH to the left side of
differential carrier in 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
Drive pinion bearing preload
12.7 — 32.4 N (1.3 — 3.3 kgf, 2.9 — 7.3 lbf)
(at companion flange bolt hole)
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
collar
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)
DI-00398
ST2
(A) Pinion height adjusting washer
RH
LH
N
(A)
ST2
ST1
DI-00379
DI-00380
DI-00381
ST2
ST1
DI-65
DIFFERENTIALS
Rear Differential (VA-type)
(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 the 1 — 3 washers.
T = To + N
− 0.05 (mm)
(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 pinion height adjusting washer of
part number 32295AA370.
3) Install the selected pinion height adjusting wash-
er on drive pinion, and press the rear bearing cone
into position using ST.
ST
398177700
INSTALLER
4) Insert the drive pinion into differential carrier, in-
stall the previously selected bearing preload adjust-
ing collar 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 collar, then install the pilot bearing.
T
Thickness of pinion height adjusting
washer mm (in)
To
Thickness of washer temporally
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 collar
(C) Bearing preload adjusting washer
(D) Differential carrier
(A) Pilot bearing
(B) Collar
(D)
(A)
(B)
(C)
DI-00382
ST
DI-00383
DI-00389
(A)
(B)
DI-66
DIFFERENTIALS
Rear Differential (VA-type)
7) Fit a new oil seal using ST.
NOTE:
• Press-fit until end of oil seal is 1 mm (0.04 in) in-
ward from end of carrier.
• Apply grease to the oil seal lips.
ST
499277200
INSTALLER
8) Press-fit the companion flange using ST.
NOTE:
Be careful not to damage the bearing.
ST
899874100
INSTALLER
9) Install a new self-locking nut, and secure the
companion flange using ST, and tighten the nut.
ST
498427200
FLANGE WRENCH
Tightening torque:
191 N
⋅
m (19.5 kgf-m, 141 ft-lb)
10) Install the hypoid driven gear on differential
case.
NOTE:
• Tighten diagonally while tapping the bolt heads.
• 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.
Tightening torque:
62 N
⋅
m (6.3 kgf-m, 45.6 ft-lb)
11) Press the side bearing into differential case us-
ing ST.
ST
398487700
DRIFT
12) Assemble holders.
(1) Install the new oil seal into holder RH and
LH.
ST
498447100
INSTALLER
ST
DI-00089
DI-00384
ST
DI-00372
ST
DI-00371
ST
DI-00095
ST
DI-00166
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