Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 497
DI-33
Rear Differential (T-type)
DIFFERENTIALS
2) Adjusting drive pinion height:
Adjust the drive pinion height with pinion height ad-
justing washer installed between the rear bearing
cone and the back of pinion gear.
(1) Attach the ST2.
NOTE:
At this time, install a provisionally selected or previ-
ously used pinion height adjusting washer. Mea-
sure and record the thickness.
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 differ-
ential carrier 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 (0.0079 in)
(Example of calculation)
To = 3.39 mm (0.1335 in)
N = 0.24 mm (0.0094 in)
H = + 1
T = 3.39 mm (0.1335 in) + 0.24 mm (0.0094 in)
– 0.01 mm (0.0004 in) – 0.20 mm (0.0079 in) =
3.42 mm (0.1346 in)
Result: Thickness = 3.42 mm (0.1346 in)
Therefore use washer 383605200.
(A) Pinion height adjusting washer
DI-00083
RH
LH
N
(A)
ST2
ST3
ST1
DI-00084
ST2
ST1
T
Thickness of pinion height adjusting washer
mm (in)
To
Thickness of washer temporarily 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-34
Rear Differential (T-type)
DIFFERENTIALS
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 the differential carrier,
and install the preselected preload adjusting spac-
er and washer.
5) Press-fit the front bearing cone with ST1, ST2
and ST3.
ST1 398507703
DUMMY COLLAR
ST2 399780104
WEIGHT
ST3 899580100
INSTALLER
6) Insert the spacer, then press-fit the pilot bearing
with ST1 and ST2.
NOTE:
Use a new pilot bearing.
ST1 399780104
WEIGHT
ST2 899580100
INSTALLER
7) Using the ST, install the oil seal.
NOTE:
• Use a new oil seal.
• Press-fit until the oil seal end comes 1 mm (0.04
in) inward from end of carrier.
• Apply differential gear oil 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) Preload adjusting spacer
(C) Preload adjusting washer
(D) Differential carrier
DI-00085
ST
DI-00704
(A)
(B)
(C)
(D)
DI-00087
ST3
ST1
ST2
DI-00088
ST2
ST1
DI-00089
ST
DI-00090
ST1
ST2
DI-35
Rear Differential (T-type)
DIFFERENTIALS
9) Apply seal material on the drive pinion shaft
thread and new self-locking nut seat.
Seal material:
THREE BOND 1324 (Part No. 004403042) or
equivalent
10) Attach the new self-locking nut and use the ST
to fix the companion flange in place, then tighten
the self-locking nut.
Tightening torque:
181.5 N·m (18.5 kgf-m, 133.9 ft-lb)
ST 498427200
FLANGE WRENCH
11) Check the initial torque or initial load.
Initial load:
18.1 — 38.8 N (1.8 — 4.0 kgf, 4.1 — 8.7 lbf)
Initial torque:
0.69 — 1.47 N·m (0.07 — 0.15 kgf-m, 0.51 —
1.08 ft-lb)
12) Assembling differential case
Install the side gears and pinion mate gears, with
their side gear thrust washers and pinion mate
shaft, into the differential case.
NOTE:
• Apply gear oil on both sides of the washer and on
the side gear shaft before installing.
• Insert the pinion mate shaft into the differential
case by aligning the lock pin holes.
(1) Measure the side gear backlash.
Side gear backlash:
0.10 — 0.20 mm (0.004 — 0.008 in)
DI-00091
ST
DI-00715
DI-00481
DI-00686
DI-00240
DI-36
Rear Differential (T-type)
DIFFERENTIALS
(2) Adjust the backlash as specified by select-
ing side gear thrust washer.
(3) Check the condition of rotation after apply-
ing oil to the gear tooth surfaces and washer
surfaces.
(4) Drive the pinion shaft lock pin into the differ-
ential case.
NOTE:
Use a new pinion shaft lock pin.
ST1 899904100
STRAIGHT PIN REMOVER
13) Install the driven gear to the differential case.
NOTE:
• Before installing bolts, apply seal material to bolt
threads.
Seal material:
THREE BOND 1324 (Part No. 004403042) or
equivalent
• Make sure there is no clearance between the dif-
ferential case and driven gear.
• Tighten opposing bolts in order.
Tightening torque:
103 N·m (10.5 kgf-m, 76.0 ft-lb)
14) Using the ST, press-fit the side bearing cone to
the differential case.
ST 398487700
DRIFT
15) Using the ST, press-fit the side bearing outer
race to the side retainer.
CAUTION:
Make sure that the bearing outer races and
cones are properly assembled.
ST 398417700
DRIFT
16) Side retainer shim adjustment
(1) The hypoid driven gear backlash and side
bearing preload can be adjusted by the side re-
tainer shim thickness.
(2) Install the differential case assembly into dif-
ferential carrier in the reverse order of disas-
sembly.
NOTE:
Be careful not to hit the teeth of hypoid driven gear
against the differential carrier.
(3) Install the side retainer shim.
NOTE:
• Be careful not to mix up the side retainer shim
RH and LH.
• Replace broken or corroded side retainer shims
with a new part of the same thickness.
Side gear thrust washer
Part No.
Thickness mm (in)
383445201
0.75 — 0.80 (0.0295 — 0.0315)
383445202
0.80 — 0.85 (0.0315 — 0.0335)
383445203
0.85 — 0.90 (0.0335 — 0.0354)
DI-00068
DI-00095
ST
Side retainer shim
Part No.
Thickness mm (in)
383475201
0.20 (0.0079)
383475202
0.25 (0.0098)
383475203
0.30 (0.0118)
383475204
0.40 (0.0157)
383475205
0.50 (0.0197)
DI-00324
ST
DI-00065
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