Subaru Legacy (2005 year). Service manual — part 734

DI-43

DIFFERENTIALS

Rear Differential (T-type)

18) If proper tooth contact is not obtained, once
again adjust the drive pinion height by changing RH
and LH side bearing retainer shims and the hypoid
gear backlash.
19) Remove the RH and LH side bearing retainer.
20) Install a new O-ring to side bearing retainer of
both side.
21) Using the ST, install the oil seal to the side
bearing retainer of both side.
ST

398437700

DRIFT

22) Align the arrow mark on differential carrier with
the mark on side retainer during installation.

23) Apply liquid gasket to the bolt of arrow mark,
and install the side bearing retainer.

Liquid gasket:

THREE BOND 1105 (Part No. 004403010) or
equivalent

Tightening torque:

10.3 N

⋅

m (1.05 kgf-m, 7.6 ft-lb)

24) Install the new gasket and rear cover to the dif-
ferential carrier, and tighten the bolts to specified
torque.

Tightening torque:

29 N

⋅

m (3.0 kgf-m, 21.4 ft-lb)

25) Install the breather cap.
26) Install the drain plug and filler plug.

Tightening torque:

49 N

⋅

m (5.0 kgf-m, 36.2 ft-lb)

E: INSPECTION

Wash all the disassembled parts clean, and exam-
ine them for wear, damage and other defects. Re-
pair or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
• If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact. Re-
place the gear if excessively worn or incapable of
adjustment.
• If crack, score or seizure is evident, replace as a
set. Slight damage of tooth can be corrected by oil
stone or the like.
2) Side gear and pinion mate gear
• Replace if crack, score or other defects are evi-
dent on tooth surface.
• Replace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearings
Replace if seizure, peeling, wear, rust, dragging
during rotation, noise or other defect is evident.
4) Thrust washers of side gear and pinion mate
gear:
Replace if seizure, flaw, abnormal wear or other
defect is evident.
5) Oil seal
Replace if deformed or damaged, and at every dis-
assembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.

(A) Arrow mark

(A)

DI-00097

DI-00461

DI-00113

DI-44

DIFFERENTIALS

Rear Differential (T-type)

8) Companion flange
Replace if the oil seal lip contacting surfaces have
flaws.

1. SIDE GEAR BACKLASH

Using a dial gauge, check the backlash of the side
gear. (Model without LSD)

Side gear backlash:

0.1 — 0.2 mm (0.004 — 0.008 in)

If the side gear backlash is not within the specifica-
tion, adjust it as specified by selecting side gear
thrust washer.

2. HYPOID DRIVEN GEAR BACKLASH

Using a dial gauge, check the backlash of hypoid
driven gear.

Hypoid driven gear backlash:

0.1 — 0.2 mm (0.004 — 0.008 in)

If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or re-
pair if necessary.

3. HYPOID DRIVEN GEAR RUNOUT ON ITS
BACK SURFACE

Using a dial gauge, check the hypoid driven gear
runout on its back surface.

Hypoid driven gear runout on its back surface:

0.05 mm (0.0020 in)

If the hypoid driven gear runout exceeds 0.05 mm
(0.0020 in), replace the hypoid driven gear.

4. TOOTH CONTACT BETWEEN HYPOID
DRIVEN GEAR AND DRIVE PINION

Inspect the tooth contact between hypoid driven
gear and drive pinion. <Ref. to DI-35, ASSEMBLY,
Rear Differential (T-type).>

5. TOTAL PRELOAD

Using a spring balance, check the total preload.

Total preload:

20.7 — 54.4 N (2.1 — 5.5 kgf, 4.7 — 12.2 lbf)

If the total preload is not within the specification,
adjust the side bearing retainer shims.

DI-00315

DI-00099

DI-00101

DI-00117

DI-45

DIFFERENTIALS

Rear Differential (T-type)

6. COMPANION FLANGE

1) If rust or dirt is attached to the companion flange,
remove them.
2) Set a dial gauge at a companion flange surface
(mating surface of propeller shaft and companion
flange), and then measure the companion flange
runout.

Limit of runout:

0.08 mm (0.0031 in)

3) Set the gauge inside of the companion flange,
and measure the runout.

Limit of runout:

0.08 mm (0.0031 in)

4) If either runout exceeds the limit, move the
phase of companion flange and drive pinion 90

°

each, and find the point where the runout is within
the limit.
5) If the runout exceeds the limit after changing the
phase, replace the companion flange and recheck
the runout.
6) If the runout exceeds the limit after replacing the
companion flange, the drive pinion may be assem-
bled incorrectly or bearing is faulty.

F: ADJUSTMENT

1. SIDE GEAR BACKLASH

Adjust the side gear backlash.
<Ref. to DI-35, ASSEMBLY, Rear Differential (T-
type).>

2. HYPOID DRIVEN GEAR BACKLASH

Adjust hypoid driven gear backlash.
<Ref. to DI-35, ASSEMBLY, Rear Differential (T-
type).>

3. TOOTH CONTACT BETWEEN HYPOID
DRIVEN GEAR AND DRIVE PINION

Adjust the tooth contact between hypoid driven
gear and drive pinion gear.
<Ref. to DI-35, ASSEMBLY, Rear Differential (T-
type).>

4. TOTAL PRELOAD

Adjust the side bearing shim.
<Ref. to DI-35, ASSEMBLY, Rear Differential (T-
type).>

DI-00360

DI-00361

DI-46

DIFFERENTIALS

Rear Differential (VA-type)

5. Rear Differential (VA-type)

A: REMOVAL

1) Disconnect the ground cable from battery.
2) Move the select lever or gear shift lever to neu-
tral.
3) Loosen the wheel nuts.
4) Release the parking brake.
5) Lift-up the vehicle.
6) Remove the rear wheels.
7) Remove the rear exhaust pipe and muffler.
8) Remove the heat shield cover.

9) Remove the propeller shaft.
<Ref. to DS-10, REMOVAL, Propeller Shaft.>
10) Prepare the transmission jack and band.

11) Loosen the self-locking nuts which hold the
rear differential to rear crossmember.

12) Remove the DOJ of rear drive shaft from rear
differential.

13) Remove the nuts which hold the rear differen-
tial front member.

14) Support the rear differential with transmission
jack.

15) Remove the rear differential front member.
16) Secure the rear differential using band.
17) Remove the self-locking nuts which hold the
rear differential to rear crossmember.

AT-01331

DI-00268

DI-00269

(A) Tire lever

(B) Bolt

DI-00287

(A)

(B)

DI-00358

DI-00273