Subaru Legacy (2005 year). Service manual — part 598

5AT-91

AUTOMATIC TRANSMISSION

Drive Pinion Shaft Assembly

6) If tooth contact is correct, mark the retainer posi-
tion and loosen it. After fitting a new O-ring and oil
seal, screw in the retainer to the marked position.
Tighten the lock plate (A) to specified torque.

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

AT-01986

(A)

5AT-92

AUTOMATIC TRANSMISSION

Front Differential Assembly

34.Front Differential Assembly

A: REMOVAL

1) Remove the transmission assembly from vehi-
cle. <Ref. to 5AT-38, REMOVAL, Automatic Trans-
mission Assembly.>
2) Pull out the torque converter assembly. <Ref. to
5AT-70, REMOVAL, Torque Converter Assembly.>
3) Remove the transmission harness connector
from stay.
4) Remove the oil charge pipe. <Ref. to 5AT-69,
REMOVAL, Oil Charge Pipe.>
5) Remove the ATF filter inlet and outlet pipes.
<Ref. to 5AT-60, REMOVAL, ATF Filter.>
6) Separate the converter case and transmission
case. <Ref. to 5AT-82, REMOVAL, Converter
Case.>
7) Remove the differential side retainers using ST.

NOTE:
Hold the differential case assembly by hand to
avoid damaging the retainer mounting hole of con-
verter case.
ST

18630AA010

WRENCH COMPL RETAIN-
ER

8) Remove the differential assembly without dam-
aging the installation part of retainer.

B: INSTALLATION

1) When installing the differential assembly (A) to
case, be careful not to damage the inside of case
(particularly, the differential side retainer mating
surface).

2) Install the O-ring to left and right side retainer.
3) Install the side retainers using ST. <Ref. to 5AT-
92, REMOVAL, Front Differential Assembly.>
ST

18630AA010

WRENCH COMPL RETAIN-
ER

4) Adjust the front differential backlash. <Ref. to
5AT-95, ADJUSTMENT, Front Differential Assem-
bly.>
5) Install the lock plate (A).

Tightening torque:

25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

6) Install the converter case to transmission case.
<Ref. to 5AT-82, INSTALLATION, Converter
Case.>
7) Install the transmission harness connector to the
stay.
8) Install the ATF filter pipe. <Ref. to 5AT-60, IN-
STALLATION, ATF Filter.>
9) Install the oil charge pipe with a O-ring. <Ref. to
5AT-69, INSTALLATION, Oil Charge Pipe.>
10) Install the torque converter assembly. <Ref. to
5AT-70, INSTALLATION, Torque Converter As-
sembly.>
11) Install the transmission assembly into vehicle.
<Ref. to 5AT-42, INSTALLATION, Automatic
Transmission Assembly.>

C: DISASSEMBLY

1. DIFFERENTIAL CASE ASSEMBLY

1) Remove the taper roller bearing using ST and
press.
ST

498077000

REMOVER

AT-01987

(A)

AT-01988

(A)

AT-00216

5AT-93

AUTOMATIC TRANSMISSION

Front Differential Assembly

2) Secure the case in a vise, remove the hypoid
driven gear tightening bolts, and then separate the
hypoid driven gear into case (RH) and case (LH).

3) Pull out the straight pin and shaft, and then re-
move the differential bevel gear, washer and differ-
ential bevel pinion.

2. SIDE RETAINER

NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
1) Remove the O-ring.

2) Remove the oil seal.

3) Remove the split pin, and then remove the claw.
ST

398527700

PULLER ASSY

4) Attach two claws to the outer race, and set the
ST to side retainer.
ST

398527700

PULLER ASSY

5) Attach the removed claws to original position,
and install the pin and split pin.
6) Hold the shaft of ST to avoid removing from side
retainer, and then remove the bearing outer race.
ST

398527700

PULLER ASSY

(A) Hypoid driven gear

(B) Differential case (RH)

(C) Differential case (LH)

(A) Differential case (RH)

(B)

AT-00217

(A)

(C)

AT-00218

(A)

AT-00219

(A) Claw

(B) Split pin

(C) Pin

(A) Shaft

(B) Claw

AT-00220

AT-00221

AT-00222

5AT-94

AUTOMATIC TRANSMISSION

Front Differential Assembly

NOTE:
Replace the bearing inner and outer races as a sin-
gle unit.

D: ASSEMBLY

1. DIFFERENTIAL CASE ASSEMBLY

1) Install the washer, differential bevel gear and dif-
ferential bevel pinion in the differential case (RH).
Insert the pinion shaft.
2) Install the straight pin in reverse direction.

3) Install the washer and differential bevel gear to
differential case (LH). Put the differential case (RH)
on the case, and then combine both cases.
4) Install the hypoid driven gear and secure by
tightening the bolt.

Tightening torque:

62 N

⋅

m (6.3 kgf-m, 45.7 ft-lb)

5) Measurement of backlash (Selection of washer)

(1) Install the SUBARU genuine axle shaft to
differential case.

Part No. 38415AA070

AXLE SHAFT

(2) Measure the gear backlash using ST1 and
ST2, and then insert the ST2 though the access
window of case.

ST1

498247001

MAGNET BASE

ST2

498247100

DIAL GAUGE

NOTE:
• Measure the backlash by applying a pinion tooth
between two bevel gear teeth.
• Fix the bevel pinion gear in place with a screw-
driver or similar tool when measuring.

Specification:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

(3) If the backlash is not within specification, se-
lect a washer from the table below.

6) Using the ST, install the taper roller bearing.
ST

398487700

DRIFT

(A) Shaft

(B) Side retainer

(A) Differential case (RH)

AT-00223

AT-00218

(A)

(A) Hypoid driven gear

(B) Differential case (RH)

(C) Differential case (LH)

Washer

Part No.

Thickness mm (in)

803038021

0.95 (0.037)

803038022

1.00 (0.039)

803038023

1.05 (0.041)

(B)

AT-00217

(A)

(C)

AT-00224

ST2

ST1