Subaru Legacy (2005 year). Service manual — part 732
DI-35
DIFFERENTIALS
Rear Differential (T-type)
16) Remove the front oil seal from differential carri-
er using ST.
ST
398527700
PULLER ASSY
17) Remove the pilot bearing together with front
bearing cone and collar using ST.
ST
398467700
DRIFT
18) When replacing the bearings, hit out the front
bearing cup and rear bearing cup in this order using
a brass bar.
D: ASSEMBLY
NOTE:
• Assemble in the reverse order of disassembly.
• Check and adjust each part during assembly.
• Keep the shims and washers in order, so that
they are not improperly installed.
• Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
• Apply gear oil to the bearings and thrust washers
when installing them.
• Be careful not to mix up the bearing races RH
and LH.
• Use new O-rings and gasket.
• Replace the oil seals with new ones at every dis-
assembly. Apply grease to the lips when installing
the oil seals.
• Be careful not to mix up the differential oil seal
RH and LH.
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) Press the rear bearing race into differential
carrier with ST1 and ST2.
ST1
398477701
HANDLE
ST2
398477703
DRIFT 2
(2) Install the front bearing race to differential
carrier using ST1 and ST2.
ST1
398477701
HANDLE
ST2
398477702
DRIFT
(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
DI-00463
ST2
ST1
DI-00079
DI-36
DIFFERENTIALS
Rear Differential (T-type)
(3) Measure and record the thickness of pinion
height 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.
(4) Insert the ST1 into carrier with pinion height
adjusting washer and rear bearing cone fitted
onto it.
NOTE:
Use new rear bearing cone.
(5) Install the preload adjusting collar and
washer, front bearing cone, ST2, companion
flange, and washer and drive pinion nut.
ST1
398507702
DUMMY SHAFT
ST2
398507703
DUMMY COLLAR
(6) 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 ST1
with ST2 as shown in the figure.
• Measure the preload in direction of tangent to
flange.
ST1
398507702
DUMMY SHAFT
ST2
398507704
BLOCK
Tightening torque:
181 N
⋅
m (18.5 kgf-m, 134 ft-lb)
(A) Pinion height adjusting washer
(B) Preload adjusting collar
(C) Preload adjusting washer
(B)
(A)
(C)
ST2
ST1
DI-00080
DI-00117
Drive pinion bearing preload
18.1 — 38.8 N (1.8 — 4.0 kgf, 4.1 — 8.7 lbf)
at companion flange bolt hole
Preload adjust-
ing washer
Part No.
Thickness mm (in)
383705200
2.59 (0.1020)
383715200
2.57 (0.1012)
383725200
2.55 (0.1004)
383735200
2.53 (0.0996)
383745200
2.51 (0.0988)
383755200
2.49 (0.0980)
383765200
2.47 (0.0972)
383775200
2.45 (0.0965)
383785200
2.43 (0.0957)
383795200
2.41 (0.0949)
383805200
2.39 (0.0941)
383815200
2.37 (0.0933)
383825200
2.35 (0.0925)
383835200
2.33 (0.0917)
383845200
2.31 (0.0909)
ST1
ST2
DI-00081
DI-00117
DI-37
DIFFERENTIALS
Rear Differential (T-type)
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
398507702
DUMMY SHAFT
ST2
398507701
DIFFERENTIAL CARRIER
GAUGE
ST3
398507703
DUMMY COLLAR
(2) 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
398507702
DUMMY SHAFT
ST2
398507701
DIFFERENTIAL CARRIER
GAUGE
(3) 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.
T = To + N
− (H × 0.01) − 0.20 mm
NOTE:
Use copies of this page.
(Example of calculation)
To = 2.20 + 1.20 = 3.40 mm
N = 0.23 mm H = + 1
T = 3.40 + 0.23
− 0.01 − 0.20 = 3.42
Result: Thickness = 3.42 mm
Therefore use the pinion height adjusting wash-
er of part number 383605200.
Preload adjust-
ing collar
Part No.
Length mm (in)
383695201
56.2 (2.213)
383695202
56.4 (2.220)
383695203
56.6 (2.228)
383695204
56.8 (2.236)
383695205
57.0 (2.244)
383695206
57.2 (2.252)
(A) Pinion height adjusting washer
RH
LH
N
(A)
ST2
ST3
ST1
DI-00083
ST2
ST1
DI-00084
T
Thickness of pinion height adjusting
washer mm (in)
To
Thickness of washer temporally
inserted mm (in)
N
Clearance of thickness gauge mm (in)
H
Figure marked on drive pinion head
Memo:
Pinion height adjusting washer
Part No.
Thickness mm (in)
383495200
3.09 (0.1217)
383505200
3.12 (0.1228)
383515200
3.15 (0.1240)
383525200
3.18 (0.1252)
383535200
3.21 (0.1264)
383545200
3.24 (0.1276)
383555200
3.27 (0.1287)
383565200
3.30 (0.1299)
383575200
3.33 (0.1311)
383585200
3.36 (0.1323)
383595200
3.39 (0.1335)
383605200
3.42 (0.1346)
383615200
3.45 (0.1358)
383625200
3.48 (0.1370)
383635200
3.51 (0.1382)
383645200
3.54 (0.1394)
383655200
3.57 (0.1406)
383665200
3.60 (0.1417)
383675200
3.63 (0.1429)
383685200
3.66 (0.1441)
DI-38
DIFFERENTIALS
Rear Differential (T-type)
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 differential carrier, in-
stall the selected bearing preload adjusting collar
and washer.
5) Press-fit the front bearing cone into case with
ST1, ST2 and ST3.
ST1
398507703
DUMMY COLLAR
ST2
399780104
WEIGHT
ST3
899580100
INSTALLER
6) Insert the collar, then press-fit the pilot bearing
with ST1 and ST2.
ST1
399780104
WEIGHT
ST2
899580100
INSTALLER
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
498447120
INSTALLER
8) Press-fit the companion flange with ST1 and
ST2.
NOTE:
Be careful not to damage the bearing.
ST1
899874100
INSTALLER
ST2
399780104
WEIGHT
(A) Drive pinion
(B) Bearing preload adjusting collar
(C) Bearing preload adjusting washer
(D) Differential carrier
ST
DI-00085
(A)
(B)
(C)
(D)
DI-00086
ST3
ST1
ST2
DI-00087
ST2
ST1
DI-00088
ST
DI-00089
ST1
ST2
DI-00090
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