Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 413
5MT-73
Front Differential Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
E: INSPECTION
Repair or replace the differential gear in the follow-
ing cases:
• When the hypoid drive gear and drive pinion
shaft tooth surfaces are damaged, excessively
worn, or seized.
• When the roller bearing on the drive pinion shaft
has a worn or damaged roller path.
• When there is damage, wear or seizure of the dif-
ferential bevel pinion, differential bevel gear, ad-
justing washer, pinion shaft or straight pin.
• When the differential case sliding surfaces are
worn or damaged.
1. BEVEL PINION GEAR BACKLASH
Measure the backlash between the differential bev-
el gear and differential bevel pinion. If backlash is
out of specifications, install a suitable adjusting
washer to adjust. <Ref. to 5MT-74, ADJUSTMENT,
Front Differential Assembly.>
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)
2. HYPOID GEAR BACKLASH
1) Set the ST1, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface on
the right corner, and check the backlash.
ST1 498247001
MAGNET BASE
ST2 498247100
DIAL GAUGE
ST3 498255400
PLATE
2) Install SUBARU genuine axle shafts to both
sides, rotate in the inversion direction so that the
gauge contacts the tooth surface, and read the dial
gauge
Part No. 38415AA100 Axle shaft
Backlash
0.13 — 0.18 mm (0.0051 — 0.0071 in)
NOTE:
If the backlash is outside the specified range, ad-
just it by turning the side retainer in the right side
case.
(A) Drive pinion shaft
(B) Hypoid driven gear
(C) Pinion shaft
(D) Straight pin
(E) Adjusting washer
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Roller bearing
(I) Differential case
(I)
(H)
(D)
(C)
(B)
(E)
(F)
(G)
(F)
(E)
(A)
(H)
(G)
MT-01074
MT-00285
ST1
ST2
MT-00293
ST1
ST2
ST3
5MT-74
Front Differential Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
3. TOOTH CONTACT OF HYPOID GEAR
Check tooth contact of hypoid gear as follows: Ap-
ply a thin uniform coat of red lead on both teeth sur-
faces on 3 or 4 teeth of the hypoid gear. Move the
hypoid gear back and forth by turning the transmis-
sion main shaft until a definite contact pattern is de-
veloped on the hypoid gear, and judge whether
face contact is correct. When the contact pattern is
not correct, adjust. <Ref. to 5MT-74, ADJUST-
MENT, Front Differential Assembly.>
• Tooth contact is correct.
F: ADJUSTMENT
1. BEVEL PINION GEAR BACKLASH
1) Disassemble the front differential assembly.
<Ref. to 5MT-70, DISASSEMBLY, Front Differen-
2) Select a suitable adjusting washer for the differ-
ential bevel gear from the table and install.
3) Adjust until the standard value is obtained.
Backlash:
Standard
0.13 — 0.18 mm (0.0051 — 0.0071 in)
2. HYPOID GEAR BACKLASH
Adjust the backlash by turning the side retainer in
the RH side case.
ST 18630AA010 WRENCH COMPL RETAIN-
ER
NOTE:
Each time the side retainer rotates by one notch
(A), the backlash changes by 0.05 mm (0.020 in).
(A) Toe
(B) Coast side
(C) Heel
(D) Drive side
Adjusting washer
Part No.
Thickness mm (in)
803038021
0.925 — 0.950
(0.0364 — 0.0374)
803038022
0.975 — 1.000
(0.0384 — 0.0394)
803038023
1.025 — 1.050
(0.0404 — 0.0413)
MT-01402
(B)
(D)
(C)
(A)
MT-00176
ST
MT-02603
(A)
5MT-75
Front Differential Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
3. TOOTH CONTACT OF HYPOID GEAR
1) Adjust until correct teeth contact is obtained.
2) Check tooth contact, and perform the adjust-
ment as follows.
• Correct tooth contact
Check item: Tooth contact surface is slightly
shifted toward the toe side under a no-load con-
dition. (When driving, it moves towards the heel
side.)
• Face contact
Check item: Backlash is too large.
Contact pattern
Corrective action: Tighten the side retainer to move
the driven gear closer to the drive pinion shaft.
• Flank contact
Check item: Backlash is too small.
Contact pattern
Corrective action: Loosen the side retainer to move
the driven gear away from the drive pinion shaft.
• Toe contact (inside contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Increase the thickness of drive
pinion shim and tighten the side retainer to move
the driven gear closer to the drive pinion shaft ac-
cording to the procedure for bringing drive pinion
shaft away from driven gear.
(A) Toe side
(B) Heel side
(A)
(B)
MT-01401
AT-00208
MT-01799
AT-00209
MT-01800
AT-00210
AT-00213
5MT-76
Front Differential Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL
• Heel contact (outside end contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of drive
pinion shim and loosen the side retainer to move
the driven gear away from the drive pinion accord-
ing to the procedure for moving drive pinion shaft
closer to the driven gear.
AT-00211
AT-00212
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