Subaru Legacy (2005 year). Service manual — part 740
DI-67
DIFFERENTIALS
Rear Differential (VA-type)
(2) Install the bearing race into holder RH and
LH.
ST
398417700
DRIFT PUNCH
CAUTION:
Make sure that the oil seal, bearing outer race
and cone are properly assembled.
(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) Temporally tighten the side holder RH and
LH in differential carrier to install.
13) 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) Screw in the side holder LH until light con-
tact is made with ST.
ST
18630AA010
WRENCH ASSY
(3) Back off the side (hypoid driven gear side)
holder approx.1 1/2 teeth of holder, and tighten
the other side holder by approx. 2 teeth (approx.
1 1/2 + 1/2 teeth). [Back off amount of side (hy-
poid driven gear side) holder + 1/2 tooth.]
This + 1/2 tooth gives preload.
(4) Temporarily tighten the lock plate.
NOTE:
Turn over the lock plate to displace the holder 1/2
tooth.
(5) Measure the hypoid driven gear-to-drive
pinion backlash. Set the magnet base on differ-
ential carrier. Align the contact point of dial
gauge with tooth face of hypoid driven gear, and
move hypoid driven gear while holding drive pin-
ion still. Read the value indicated on dial gauge.
NOTE:
If measured backlash is not within specified range,
repeat the procedures for pinion driven gear set
backlash adjustment and differential side bearing
preload adjustment.
Backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
DI-00366
DI-00385
ST
ST
DI-00399
DI-00364
DI-00172
DI-68
DIFFERENTIALS
Rear Differential (VA-type)
14) Draw a matching mark on both differential car-
rier and holder. Remove the holder side at a time.
Replace in the original position after inserting an O-
ring and applying grease to threaded portion.
15) Tighten the bolt of lock plate to specified
torque.
Tightening torque:
25 N
⋅
m (2.5 kgf-m, 18.4 ft-lb)
16) Recheck the hypoid driven gear to pinion back-
lash.
Backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
17) Checking and adjusting the tooth contact of hy-
poid driven gear
(1) Apply an even coat of red lead on both sides
of three or four teeth on the hypoid driven gear.
Check the contact pattern after rotating the hy-
poid driven gear several revolutions back and
forth until a definite contact pattern appears on
the hypoid driven gear.
(2) When the contact pattern is incorrect, read-
just.
NOTE:
Be sure to wipe off red lead completely after adjust-
ment is completed.
• Correct tooth contact
Checking item: Tooth contact pattern is slightly
shifted toward toe side under no-load rotation.
[When loaded, contact pattern moves toward
heel.]
• Face contact
Checking item: Backlash is too large.
Contact pattern
(A) Alignment mark
(B) Holder
DI-00386
(B)
(A)
DI-00364
DI-00172
(A) Toe side
(B) Heel side
AT-00207
(A)
(B)
AT-00208
DI-69
DIFFERENTIALS
Rear Differential (VA-type)
Corrective action: Increase thickness of drive pin-
ion height adjusting washer in order to bring drive
pinion close to hypoid driven gear.
• Flank contact
Checking item: Backlash is too small.
Contact pattern
Corrective action: Reduce thickness of drive pinion
height adjusting washer in order to bring drive pin-
ion away from hypoid driven gear.
• Toe contact (inside end contact)
Checking item: Contact areas is small
Contact pattern
Corrective action: Reduce thickness of drive pinion
height adjusting washer in order to bring drive pin-
ion away from hypoid driven gear.
• Heel contact (outside end contact)
Checking item: Contact areas is small
Contact pattern
Corrective action: Increase thickness of drive pin-
ion height adjusting washer in order to bring drive
pinion close to hypoid driven gear.
18) If proper tooth contact is not obtained, once
again adjust the drive pinion height and the differ-
ential side bearing preload (already mentioned)
and the hypoid gear backlash.
AT-00212
AT-00209
AT-00213
AT-00210
AT-00213
AT-00211
AT-00212
DI-70
DIFFERENTIALS
Rear Differential (VA-type)
19) Install the new gasket and rear cover to differ-
ential carrier and tighten the bolts to specified
torque.
Tightening torque:
25 N
⋅
m (2.5 kgf-m, 18.4 ft-lb)
E: INSPECTION
Wash all the disassembled parts clean, and exam-
ine them for wear, damage and other defects. Re-
pair or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
• If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact. Re-
place the gear if excessively worn or incapable of
adjustment.
• If crack, score or seizure is evident, replace as a
set. Slight damage of tooth can be corrected by oil
stone or the like.
2) Side gear and pinion mate gear
• Replace if crack, score or other defects are evi-
dent on tooth surface.
• Replace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearings
Replace if seizure, peeling, wear, rust, dragging
during rotation, noise or other defect is evident.
4) Thrust washers of side gear and pinion mate
gear:
Replace if seizure, flaw, abnormal wear or other
defect is evident.
5) Oil seal
Replace if deformed or damaged, and at every dis-
assembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal lip contacting surfaces have
flaws.
1. SIDE GEAR BACKLASH
Using a dial gauge, check the backlash of the side
gear. (VA1-type only)
Side gear backlash:
0.05 — 0.15 mm (0.0020 — 0.0059 in)
If the side gear backlash is not within the specifica-
tion, adjust it as specified by selecting side gear
thrust washer.
2. HYPOID DRIVEN GEAR BACKLASH
Using a dial gauge, check the backlash of hypoid
driven gear.
Hypoid driven gear backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or re-
pair if necessary.
3. TOOTH CONTACT BETWEEN HYPOID
DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between hypoid driven
gear and drive pinion. <Ref. to DI-55, ASSEMBLY,
Rear Differential (VA-type).>
DI-00387
DI-00240
DI-00099
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