Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 501
DI-49
Rear Differential (T-type)
DIFFERENTIALS
• Face contact
Check item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of pinion
height adjusting washer according to the proce-
dure for bringing drive pinion close to hypoid
driven gear side.
• Flank contact
Check item: Backlash is too small.
Contact pattern
Corrective action: Reduce the thickness of pin-
ion height adjusting washer according to the
procedure for bringing drive pinion away from
hypoid driven gear.
AT-00208
AT-00212
AT-00209
AT-00213
DI-50
Rear Differential (T-type)
DIFFERENTIALS
• Toe contact (inside contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of pin-
ion height adjusting washer according to the
procedure for bringing drive pinion away from
hypoid driven gear.
• Heel contact (outside end contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Increase thickness of pinion
height adjusting washer according to the proce-
dure for bringing drive pinion close to hypoid
driven gear side.
27) If proper tooth contact is not obtained, readjust
the drive pinion height by changing the RH and LH
side retainer shims and the hypoid gear backlash.
28) Remove the RH and LH side retainers.
29) Install the O-ring to left and right side retainers.
NOTE:
Use new O-rings.
30) Install the oil seal to the side retainers on both
sides. <Ref. to DI-56, REPLACEMENT, Rear Dif-
31) Align the arrow mark on the differential carrier
with the arrow mark on the side retainer during in-
stallation.
AT-00210
AT-00213
(A) Arrow mark (on the side retainer)
(B) Arrow mark (on the differential carrier)
AT-00211
AT-00212
DI-00543
(B)
(A)
DI-51
Rear Differential (T-type)
DIFFERENTIALS
32) Apply liquid gasket to the bolts indicated by ar-
rows, and tighten the side retainer bolt.
Liquid gasket:
THREE BOND 1110F (Part No. K0879Y0021),
THREE BOND 1110B or equivalent
Tightening torque:
10.5 N·m (1.1 kgf-m, 7.7 ft-lb)
33) Install the gasket and rear cover, and tighten
the bolts to specified torque.
NOTE:
Use a new gasket.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
34) Install the air breather cap.
NOTE:
When installing the air breather cap, do not tap sec-
tion (A). Be sure to tap section (B) to install.
35) Install the drain plug.
NOTE:
Use a new gasket.
Tightening torque:
60 N·m (6.1 kg-m, 44.3 ft-lb)
36) Install the oil temperature switch.
NOTE:
• Install the oil temperature switch and adapter as
a unit.
• After installing the rear differential assembly to
the vehicle, fill the gear oil, then use a new gasket,
and tighten to the specified torque. <Ref. to DI-19,
REPLACEMENT, Differential Gear Oil.>
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 there is evidently an abnormal tooth contact,
find out the cause and adjust until the teeth contact
correctly. Replace the gear if there is an excessive
worn or an incapable adjustment.
• If crack, cutout or seizure is found, replace the
parts as a set. Slight damage of some teeth can be
corrected by oil stone or the like.
2) Side gear and pinion mate gear (T-type (B2))
• Replace if cracks, scoring or other defects are
evident on the tooth surface.
• Replace if thrust washer contact surface is worn
or seized. Slight damages of the surface can be
corrected by oil stones or equivalent.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, noise or other defect is evident.
4) Thrust washer of side gear and pinion mate gear
(T-type (B2))
Replace if seized, flawed, abnormally worn or hav-
ing other defects.
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 sliding surfaces are abnormally worn,
burned, or cracked.
8) Companion flange
Replace if the oil seal lip contact surface shows
cracking.
DI-00461
DI-00679
(A)
(B)
DI-52
Rear Differential (T-type)
DIFFERENTIALS
9) Rear differential oil temperature switch (T-type
(H3))
Check the rear differential oil temperature switch
for continuity.
1. SIDE GEAR BACKLASH (T-TYPE (B2))
Using a dial gauge, check the backlash of side
gear.
Side gear backlash:
0.10 — 0.20 mm (0.004 — 0.008 in)
If the side gear backlash is not within the specifica-
tion, select the side gear thrust washer and adjust
the side gear backlash to the specification.
2. HYPOID DRIVEN GEAR BACKLASH
Using a dial gauge, check the backlash of hypoid
driven gear.
Hypoid driven gear backlash:
0.10 — 0.20 mm (0.004 — 0.008 in)
If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or re-
pair if necessary.
3. HYPOID DRIVEN GEAR RUNOUT ON ITS
BACK SURFACE
Using a dial gauge, check the hypoid driven gear
back surface runout.
Hypoid driven gear back surface runout:
0.05 mm (0.002 in)
If the hypoid driven gear runout exceeds specifica-
tion, replace the hypoid driven gear.
4. TOOTH CONTACT BETWEEN HYPOID
DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between the hypoid driv-
en gear and drive pinion. <Ref. to DI-31, ASSEM-
BLY, Rear Differential (T-type).>
Resistance
Criteria
Less than 1 Ω
Normal
1 MΩ or more
REPLACEMENT
DI-00534
DI-00315
DI-00099
DI-00101
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