NOTE:
• Assemble in the reverse order of disassembly.
• Check and adjust each part during assembly.
• Use a new gasket.
• 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 when installing the bearings and thrust washers.
• Be careful not to mix up the RH and LH bearing races.
• Replace the oil seal with a new part at every disassembly.
• Apply grease to the oil seal lip.
• 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 between front and rear bearings with collar and washer. Pinion height adjusting washer is not affected by this adjustment. The adjustment must not be carried out with oil seal inserted.
(1) Install the rear bearing race into the differential carrier using ST1 and ST2.
| ST1 398477701 | HANDLE |
| ST2 398477702 | DRIFT |
(2) Install the front bearing race to the differential carrier using ST1 and ST2.
| ST1 398477701 | HANDLE |
| ST2 498447110 | DRIFT |
(3) Measure and record the thickness of the pinion height adjusting washer.
NOTE:
If tooth contact (drive pinion, hypoid driven gear) is normal in the inspection before disassembling, verify that the washer is not deformed, and then reuse the used washer.
(4) Insert ST1 into the case with the pinion height adjusting washer and rear bearing cone fitted onto it.
NOTE:
Use new rear bearing cone.
(5) Install the preload adjusting collar & washer, front bearing cone, collar, companion flange, and washer & self-locking nut.
NOTE:
Use new front bearing cone.
| ST1 498447150 | DUMMY SHAFT |
| Part No. 32285AA000 | COLLAR |
|
(A) |
Pinion height adjusting washer |
|
(B) |
Preload adjusting collar |
|
(C) |
Preload adjusting washer |
|
(D) |
Collar (SUBARU genuine parts) |
(6) Turn the ST1 by hand to smooth the bearing, and tighten the self-locking nut while measuring the initial load or initial torque with a spring scale or torque wrench. Select the preload adjusting washer and collar so that the specified preload is obtained when nut is tightened 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 the flange.
| ST1 498447150 | DUMMY SHAFT |
| ST2 398507704 | BLOCK |
Tightening torque:
191 N·m (19.5 kgf-m, 141.0 ft-lb)
Initial load:
12.7 — 32.2 N (1.3 — 3.3 kgf, 2.9 — 7.2 lb)
Initial torque:
0.48 — 1.22 N·m (0.05 — 0.12 kgf-m, 0.35 — 0.90 ft-lb)
|
Preload adjusting washer | |
|
Part No. |
Thickness mm (in) |
|
38336AA000 |
1.500 (0.0591) |
|
38336AA120 |
1.513 (0.0596) |
|
38336AA010 |
1.525 (0.0600) |
|
38336AA130 |
1.538 (0.0606) |
|
38336AA020 |
1.550 (0.0610) |
|
38336AA140 |
1.563 (0.0615) |
|
38336AA030 |
1.575 (0.0620) |
|
38336AA150 |
1.588 (0.0625) |
|
38336AA040 |
1.600 (0.0630) |
|
38336AA160 |
1.613 (0.0635) |
|
38336AA050 |
1.625 (0.0640) |
|
38336AA170 |
1.638 (0.0645) |
|
38336AA060 |
1.650 (0.0650) |
|
38336AA180 |
1.663 (0.0655) |
|
38336AA070 |
1.675 (0.0659) |
|
38336AA190 |
1.688 (0.0665) |
|
38336AA080 |
1.700 (0.0669) |
|
38336AA200 |
1.713 (0.0674) |
|
38336AA090 |
1.725 (0.0679) |
|
38336AA210 |
1.738 (0.0684) |
|
38336AA100 |
1.750 (0.0689) |
|
38336AA220 |
1.763 (0.0694) |
|
38336AA110 |
1.775 (0.0699) |
|
Preload adjusting collar | |
|
Part No. |
Length mm (in) |
|
32288AA040 |
52.3 (2.059) |
|
32288AA050 |
52.5 (2.067) |
|
31454AA100 |
52.6 (2.071) |
|
32288AA060 |
52.7 (2.075) |
|
31454AA110 |
52.8 (2.079) |
|
32288AA070 |
52.9 (2.083) |
|
31454AA120 |
53.0 (2.087) |
|
32288AA080 |
53.1 (2.091) |
|
32288AA090 |
53.3 (2.098) |
2. Adjusting drive pinion height:
Adjust the drive pinion height with washer installed between the rear bearing cone and the back of pinion gear.
(1) Set the previous pinion bearing pre-load adjustment to a completed state for the ST1, ST2 and collar.
NOTE:
At this time, install a pinion height adjusting washer, temporarily selected, or the same as that used before.
| ST1 498447150 | DUMMY SHAFT |
| ST2 498505501 | DIFFERENTIAL CARRIER GAUGE |
| Part No. 32285AA000 | COLLAR |
|
(A) |
Pinion height adjusting washer |
|
(B) |
Collar (SUBARU genuine parts) |
(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 498447150 | DUMMY SHAFT |
| ST2 498505501 | DIFFERENTIAL CARRIER GAUGE |
(3) Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed washer with this one.
NOTE:
Adjust it using the 1 — 3 washers.
T = To + N − 0.05 (mm)
|
T |
Thickness of pinion height adjusting washer mm (in) |
|
|
To |
Thickness of washer temporally inserted mm (in) |
|
|
N |
Clearance of thickness gauge mm (in) |
|
|
Memo: | ||
(Example of calculation)
To = 0.15 mm
N = 0.1 mm
T = 0.15 + 0.1 − 0.05 = 0.2 mm
Result: Thickness = 0.2 mm
Therefore use part number 32295AA220.
|
Pinion height adjusting washer | |
|
Part No. |
Thickness mm (in) |
|
32295AA200 |
0.150 (0.0059) |
|
32295AA210 |
0.175 (0.0069) |
|
32295AA220 |
0.200 (0.0079) |
|
32295AA230 |
0.225 (0.0089) |
|
32295AA240 |
0.250 (0.0098) |
|
32295AA250 |
0.275 (0.0108) |
3. Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone into position with ST.
| ST 498175500 | INSTALLER |
4. Insert the drive pinion into the differential carrier, and install the preselected bearing preload adjusting collar and washer.
|
(A) |
Drive pinion |
|
(B) |
Bearing preload adjusting collar |
|
(C) |
Bearing preload adjusting washer |
|
(D) |
Differential carrier |
5. Press-fit the front bearing cone into the carrier with ST1, ST2 and collar.
| ST1 399780104 | WEIGHT |
| ST2 899580100 | INSTALLER |
| Part No. 32285AA000 | COLLAR |
|
(A) |
Collar (SUBARU genuine parts) |
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 with ST.
NOTE:
• Press-fit until the oil seal end comes 1 mm (0.04 in) inward 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 |
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 a new self-locking nut and secure the companion flange using ST, then tighten the nut.
| ST 498427200 | FLANGE WRENCH |
Tightening torque:
191 N·m (19.5 kgf-m, 141.0 ft-lb)
11. Check the initial torque and initial load.
Initial load:
12.7 — 32.2 N (1.3 — 3.3 kgf, 2.9 — 7.2 lb)
Initial torque:
0.48 — 1.22 N·m (0.05 — 0.12 kgf-m, 0.35 — 0.90 ft-lb)
12. Install the hypoid driven gear to differential case.
NOTE:
• Before installing bolts, apply seal material to bolt threads.
• Tighten diagonally while tapping the bolt heads.
SEAL MATERIAL
THREE BOND 1324 (Part No. 004403042) or equivalent
Tightening torque:
62 N·m (6.3 kgf-m, 45.8 ft-lb)
13. Press the side bearing cone into differential case using ST.
| ST 498485400 | DRIFT |
14. Assemble holders.
(1) Install the oil seal into holder RH and LH.
| ST 498447100 | INSTALLER |
(2) Install the bearing race into holder RH and LH.
| ST 398477702 | DRIFT |
CAUTION:
Make sure that the RH and LH oil seals, bearing outer races and cones are properly assembled.
(3) Install the differential assembly into differential carrier in the reverse order of disassembly.
(4) Temporally tighten the side holders RH and LH in differential carrier to install.
15. Perform the backlash adjustment between the hypoid driven gear and drive pinion, and preload adjustment of differential side bearing.
(1) Turn the drive pinion with ST for better fitting of differential side bearing.
| ST 498427200 | FLANGE WRENCH |
(2) Screw in the side holder LH until light contact is made with ST.
| ST 18630AA010 | WRENCH COMPL RETAINER |
NOTE:
• Be careful not to mix up the oil seal RH and LH.
• Do not install the O-ring at this point.
• WRENCH ASSY (499785500) can also be used.
(3) Loosen the holder on the hypoid driven gear side by approx.1 and 1/2 teeth, and tighten the other side holder by approx. 2 teeth (amount that the hypoid driven gear is turned back (1 and 1/2) + 1/2 teeth).
[Back off amount of side (hypoid driven gear side) holder + 1/2 tooth.] This + 1/2 tooth gives preload.
(4) Temporarily tighten the lock plate.
NOTE:
Turn over the lock plate to shift the holder by 1/2 tooth.
(5) Measure the hypoid driven gear-to-drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of hypoid driven gear, and move hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge.
NOTE:
If measured value of backlash is not within the specified range, repeat the procedures for pinion driven gear set backlash adjustment and the differential side bearing preload adjustment.
Backlash:
0.10 — 0.15 mm (0.004 — 0.006 in)
16. Put alignment marks on both the differential carrier and holder. Remove the holder side at a time.
Replace them in the original position after inserting an O-ring and applying grease to the threaded portion.
|
(A) |
Alignment mark |
|
(B) |
Holder |
17. Tighten the bolt of lock plate to specified torque.
Tightening torque:
25 N·m (2.5 kgf-m, 18.5 ft-lb)
18. Recheck the hypoid driven gear to pinion backlash.
Backlash:
0.10 — 0.15 mm (0.004 — 0.006 in)
19. Checking and adjusting the tooth contact of hypoid driven gear
(1) Apply an even coat of dye penetrant on both sides of three or four teeth on the hypoid driven gear. Check the contact pattern after rotating the hypoid driven gear several revolutions back and forth until a definite contact pattern appears on the hypoid driven gear.
(2) When the contact pattern is not correct, readjust.
NOTE:
Be sure to wipe off the dye penetrant completely after the adjustment is completed.
• Correct tooth contact
Check item: Tooth contact pattern is slightly shifted toward toe side under no-load rotation. (When driving, it moves towards the heel side.)
|
(A) |
Toe side |
|
(B) |
Heel side |
• Face contact
Check item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring drive pinion close to hypoid driven gear.
• Flank contact
Check item: Backlash is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.
• Toe contact (inside contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion 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 drive pinion height adjusting washer in order to bring drive pinion close to hypoid driven gear.
20. If proper tooth contact is not obtained, once again adjust the drive pinion height and the differential side bearing preload (already mentioned) and the hypoid gear backlash.
21. Install the new gasket and rear cover to the differential carrier, and tighten the bolts to specified torque.
Tightening torque:
25 N·m (2.5 kgf-m, 18.5 ft-lb)
|
(A) |
Rear cover |