Subaru Legacy IV (2008 year). Manual — part 687

4AT-96

Front Differential Assembly

AUTOMATIC TRANSMISSION

6) Install new seal pipe to converter case.

7) Install the converter case to the transmission
case. <Ref. to 4AT-81, INSTALLATION, Converter
Case.>
8) Insert the inhibitor switch connector and trans-
mission harness connector onto the stay.

9) Install the ATF cooler pipe. <Ref. to 4AT-63, IN-
STALLATION, ATF Cooler Pipe and Hose.>
10) Install the oil charge pipe together with an O-
ring. <Ref. to 4AT-66, INSTALLATION, Oil Charge
Pipe.>
11) Insert the input shaft while rotating it lightly by
hand, and then check the amount of protrusion.

Normal protrusion A:

50 — 55 mm (1.97 — 2.17 in)

12) Install the torque converter clutch assembly.
<Ref. to 4AT-67, INSTALLATION, Torque Convert-
er Clutch Assembly.>
13) Install the transmission assembly to the vehi-
cle. <Ref. to 4AT-38, INSTALLATION, Automatic
Transmission Assembly.>

C: DISASSEMBLY

1. DIFFERENTIAL CASE ASSEMBLY

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

498077000

REMOVER

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

(A) Seal pipe

(A) Transmission harness connectors

(B) Inhibitor switch connector

A Measured value

AT-00176

AT-01351

(B)

(A)

AT-03204

A

(A) Hypoid driven gear

(B) Differential case (RH)

(C) Differential case (LH)

AT-00216

(B)

AT-00217

(A)

(C)

4AT-97

Front Differential Assembly

AUTOMATIC TRANSMISSION

3) Pull out the straight pin and pinion shaft, 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 the two claws to the outer race, and set
the ST on the differential side retainer.
ST

398527700

PULLER ASSY

5) Restore the removed claws to original position,
and install the pin and split pin.

(A) Differential case (RH)

AT-00218

(A)

AT-00219

AT-00220

(A) Claw

(B) Split pin

(C) Pin

(A) Shaft

(B) Claw

AT-00221

AT-00222

4AT-98

Front Differential Assembly

AUTOMATIC TRANSMISSION

6) Hold the shaft of ST to avoid detachment from
the differential side retainer, and remove the bear-
ing outer race.
ST

398527700

PULLER ASSY

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) Attach the straight pin in the reverse direction.

3) Install the washer and differential bevel gear to
differential case (LH). Put the differential case (RH)
on the case, and assemble two 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 differential
bevel pinion tooth between two differential bevel
gear teeth.
• Fix the differential bevel pinion gear in place with
a screwdriver covered with cloth or similar tool
when measuring.

Standard:

0.13 — 0.18 mm (0.0051 — 0.0071 in)

(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)

(B)

AT-00217

(A)

(C)

AT-00224

ST2

ST1

4AT-99

Front Differential Assembly

AUTOMATIC TRANSMISSION

(3) If the backlash is out of specification, select
a washer from the table below.

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

398487700

INSTALLER

2. SIDE RETAINER

1) Install the bearing outer race to the differential
side retainer.
2) Install a new oil seal using the ST and a hammer.
ST

18675AA000

DIFFERENTIAL SIDE OIL
SEAL INSTALLER

3) Apply gear oil to a new O-ring and install.

E: INSPECTION

• Check each component for scratches, damage
or other faults.
• Measure the backlash, and then adjust it to be
within specification. <Ref. to 4AT-99, ADJUST-
MENT, Front Differential Assembly.>

F: ADJUSTMENT

1) Using the ST, screw-in the differential side re-
tainer until resistance is felt.
ST

18630AA010

WRENCH COMPL RETAINER

NOTE:
• Screw-in the RH side slightly deeper than the LH
side.
• ST

WRENCH ASSEMBLY (499787000) can

also be used.

2) Remove the oil pump housing.
3) Remove the liquid gasket from the mating sur-
face completely.
4) Install the oil pump housing assembly to the con-
verter case, and secure them by tightening the four
bolts evenly.

NOTE:
Use an old gasket or aluminum washer to prevent
damaging the mating surface of the housing.

Tightening torque:

41 N·m (4.2 kgf-m, 30.2 ft-lb)

Washer

Part No.

Thickness mm (in)

803038021

0.95 (0.037)

803038022

1.00 (0.039)

803038023

1.05 (0.041)

(A) Taper roller bearing

AT-04377

AT-00226

ST

AT-00219

AT-00227

ST

AT-00205