Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 412
5MT-69
Front Differential Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
17.Front Differential Assembly
A: REMOVAL
1) Remove the manual transmission assembly
from the vehicle. <Ref. to 5MT-23, REMOVAL,
Manual Transmission Assembly.>
2) Remove the transfer case together with the ex-
tension case assembly. <Ref. to 5MT-35, REMOV-
AL, Transfer Case and Extension Case
3) Remove the transmission case. <Ref. to 5MT-
49, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly. <Ref.
to 5MT-58, REMOVAL, Drive Pinion Shaft Assem-
5) Remove the main shaft assembly for single-
range. <Ref. to 5MT-53, REMOVAL, Main Shaft
6) Remove the front differential assembly.
NOTE:
• Do not confuse the right and left roller bearing
outer races.
• Be careful not to damage the oil seal of retainer.
7) Remove the differential side retainers using ST.
ST 18630AA010 WRENCH COMPL RETAIN-
ER
8) Remove the bearing outer race from the trans-
mission case.
ST 398527700
PULLER ASSY
B: INSTALLATION
1) Install the differential side retainers using ST.
ST 18630AA010 WRENCH COMPL RETAIN-
ER
2) Install the bearing outer race to the transmission
case.
3) Install the front differential assembly.
NOTE:
Be careful not to bend the seal lips of oil seal.
4) Install the main shaft assembly for single-range.
<Ref. to 5MT-53, INSTALLATION, Main Shaft As-
5) Install the drive pinion shaft assembly. <Ref. to
5MT-58, INSTALLATION, Drive Pinion Shaft As-
6) Install the transmission case. <Ref. to 5MT-50,
INSTALLATION, Transmission Case.>
7) Install the transfer case together with the exten-
sion case assembly. <Ref. to 5MT-35, INSTALLA-
TION, Transfer Case and Extension Case
8) Install the manual transmission assembly to the
vehicle. <Ref. to 5MT-26, INSTALLATION, Manual
MT-00162
MT-00176
ST
MT-00162
5MT-70
Front Differential Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Remove the twelve bolts and remove hypoid
driven gear.
2) Drive out the straight pin from differential assem-
bly toward hypoid driven gear side.
ST 899904100
STRAIGHT PIN REMOVER
3) Pull out the pinion shaft, and remove the differ-
ential bevel pinion, differential bevel gear and
washer.
4) Using the ST, remove the roller bearing.
ST 899524100
PULLER SET
(A) Hypoid driven gear
(A)
MT-00275
MT-00276
ST
(A) Pinion shaft
(B) Differential bevel pinion
(C) Differential bevel gear
(D) Washer
MT-00277
(A)
(D)
(D)
(C)
(C)
(B)
(B)
MT-00278
ST
5MT-71
Front Differential Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
2. SIDE RETAINER
1) Remove the O-ring.
2) Remove the oil seal.
NOTE:
Remove using the flat tip screwdriver.
D: ASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Install the differential bevel gear and differential
bevel pinion together with washer, and insert the
pinion shaft.
NOTE:
Face the chamfered side of washer toward gear.
2) Measure the backlash between differential bevel
gear and differential pinion. If backlash is out of
specifications, install a suitable washer to adjust.
<Ref. to 5MT-73, BEVEL PINION GEAR BACK-
LASH, INSPECTION, Front Differential Assem-
bly.>
NOTE:
Be sure the pinion gear teeth contacts adjacent
gear teeth during measurement.
ST1 498247001
MAGNET BASE
ST2 498247100
DIAL GAUGE
Standard backlash
0.13 — 0.18 mm (0.0051 — 0.0071 in)
3) Align the pinion shaft and differential case with
each hole, and drive the straight pin into the holes
from the hypoid driven gear using the ST.
NOTE:
• Use a new straight pin.
• Lock the straight pin after installing.
ST 899904100
STRAIGHT PIN REMOVER
(A) Differential bevel pinion
(B) Differential bevel gear
(C) Pinion shaft
MT-02742
MT-02743
MT-00284
(A)
(B)
(C)
(A) Pinion shaft
(B) Differential case
(C) Straight pin
MT-00285
ST1
ST2
MT-00286
(A)
(C)
(B)
5MT-72
Front Differential Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
4) Install the roller bearing to differential case.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
NOTE:
Be careful because the roller bearing outer races
are used as a set.
ST1 499277100
BUSHING 1-2 INSTALLER
ST2 398497701
ADAPTER
5) Install the hypoid driven gear to the differential
case using twelve bolts.
Tightening torque:
T: 62 N·m (6.3 kgf-m, 45.7 ft-lb)
2. SIDE RETAINER
1) Install the oil seal.
NOTE:
• Use a new oil seal.
• Apply transmission gear oil to the oil seal lips,
and install the oil seal while being careful not to de-
form the lip.
• Using the ST, install the oil seal by lightly tapping
with a plastic hammer.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
2) Install the O-ring.
NOTE:
• Use new O-rings.
• Apply gear oil to O-ring.
• Do not stretch or damage the O-ring.
(A) Hypoid driven gear
(B) Differential case
MT-00287
ST1
ST2
MT-01216
(B)
(A)
T
MT-00289
ST
MT-02742
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