Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Manual — part 441

6MT-101

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

4) Install the differential side retainers to both

sides, using the ST.

ST1 18630AA010

WRENCH COMPL RETAIN-

ER (RH SIDE)

ST2 18630AA000

WRENCH ASSY (LH SIDE)

NOTE:

Be careful not to damage the oil seal.

5) Inspect and adjust the hypoid gear backlash.

<Ref. to 6MT-104, HYPOID GEAR BACKLASH,

INSPECTION, Front Differential Assembly.>

6) Inspect and adjust the tooth contact. <Ref. to

6MT-98, ADJUSTMENT, Drive Pinion Shaft As-

sembly.>

7) Mark the mating positions of the left and right

side retainers and the clutch housing.

8) Remove the differential side retainers from both

sides.
NOTE:

When removing the side retainer, record how many

times it was turned to remove.

9) Install new O-rings to the side retainers on both

sides.

10) Attach the differential side retainers to both

sides.
NOTE:

When attaching, turn the side retainer the same

number of turns it took to remove, and align the

marks.

11) Install the lock plate.
Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

NOTE:

Be careful not to confuse the left and right side lock

plates.

12) Remove any remaining liquid gasket from the

clutch housing and adapter plate.

13) Apply liquid gasket to the clutch housing.
Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or

equivalent

(A) LH side
(B) RH side

(A)

(B)

MT-00657

ST1

ST2

MT-00658

(A) LH
(B) RH

MT-00659

(A)

(B)

MT-00532

6MT-102

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

14) Install the drive pinion shaft assembly. <Ref. to

6MT-94, INSTALLATION, Drive Pinion Shaft As-

sembly.>

15) Install the individual gear assemblies all at

once. <Ref. to 6MT-66, INSTALLATION, Main

Shaft Assembly.>

16) Install the transmission case. <Ref. to 6MT-60,

INSTALLATION, Transmission Case.>

17) Install the center differential. <Ref. to 6MT-57,

INSTALLATION, Center Differential.>

18) Install the transfer driven gear. <Ref. to 6MT-

55, INSTALLATION, Transfer Driven Gear.>

19) Install the extension case. <Ref. to 6MT-43, IN-

STALLATION, Extension Case.>

20) Install the neutral position switch, back-up light

switch and harness. <Ref. to 6MT-41, INSTALLA-

TION, Neutral Position Switch.> <Ref. to 6MT-39,

INSTALLATION, Back-up Light Switch.>

21) Install the manual transmission assembly to the

vehicle. <Ref. to 6MT-33, INSTALLATION, Manual

Transmission Assembly.>

C: DISASSEMBLY

1. DIFFERENTIAL CASE

1) Fix the differential assembly on a vice, and re-

move the hypoid driven gear.

ST 18270KA020 SOCKET (E20)

2) Remove the side bearing of the hypoid driven

gear using the ST.

ST 399527700

PULLER SET

3) Using the ST, remove the roller bearing.

ST 498077000

REMOVER

2. SIDE RETAINER

1) Remove the O-ring.

2) Remove the oil seal.

MT-00660

MT-00663

ST

MT-00665

ST

MT-03038

MT-03040

6MT-103

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

3) Remove the claw of ST1, and attach the claw of

ST2.

ST1 398527700

PULLER ASSY

ST2 18760AA000

CLAW

4) Remove the bearing outer race from the side re-

tainer, using the ST.

ST1 398527700

PULLER ASSY

ST2 18760AA000

CLAW

D: ASSEMBLY

1. DIFFERENTIAL CASE

1) Use the ST to attach the RH and LH bearing in-

ner races to the differential case.

ST1 398437700

INSTALLER

ST2 398497701

SEAT

CAUTION:

Do not apply pressure in excess of 20 kN (2.0

ton, 2.2 US ton, 2.0 Imp ton).
NOTE:

Always replace inner races and outer races as a

set.

2) Attach the hypoid driven gear to the differential

case.

ST 18270KA020 SOCKET (E20)
Tightening torque:

69 N·m (7.0 kgf-m, 50.9 ft-lb)

(A) Claw

(A) Side retainer

MT-00668

(A)

ST2

ST1

MT-00669

(A)

ST2

ST1

MT-00670

ST1

ST2

MT-00660

6MT-104

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

2. SIDE RETAINER

NOTE:

Install the oil seal and O-ring of side retainer after

the adjustment of backlash and tooth contact.

1) Install the bearing outer race to side retainer.

2) Using the ST, install the oil seal.

ST 18675AA000

DIFFERENTIAL SIDE OIL

SEAL INSTALLER

NOTE:

• Use a new oil seal.

• Apply oil to the oil seal lips.

3) Install the O-ring.
NOTE:

Use new O-rings.

E: INSPECTION

Repair or replace the differential in the following

cases:

• If gears are damaged, seized, or are excessively

worn.

• If differential case sliding surfaces are damaged,

seized, or are excessively worn.

• If there is damage, rust or wear in the bearings or

bearing locations.

• If the bearing does not rotate smoothly or an ab-

normal noise is emitted when turning.

1. HYPOID GEAR BACKLASH

Inspect the hypoid gear backlash. Adjust if out of

standard. <Ref. to 6MT-105, HYPOID GEAR

BACKLASH, ADJUSTMENT, Front Differential As-

sembly.>

2. TOOTH CONTACT OF HYPOID GEAR

1) Check that the hypoid gear backlash is within the

standard value. Adjust if out of standard. <Ref. to

6MT-105, HYPOID GEAR BACKLASH, ADJUST-

MENT, Front Differential Assembly.>

2) Apply a thin uniform coat of lead-free red dye on

the surfaces of 3 or 4 hypoid driven gear teeth.

3) Attach the drive pinion shaft assembly, and affix

with at least 4 bolts.
NOTE:

Use old gaskets and washers to prevent the mating

surfaces of the housing from becoming damaged.
Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

4) Turn the drive pinion shaft to the left and right for

several turns.

5) Remove the drive pinion shaft assembly, and in-

spect the mating condition of the teeth. If tooth con-

tact is not correct, perform adjustment. <Ref. to

6MT-98, ADJUSTMENT, Drive Pinion Shaft As-

sembly.>

• Correct tooth contact
NOTE:

In a no load condition, the tooth contact from the

center to the toe side is 50-60% (While driving, the

tooth contact will shift towards the heel side).

AT-00226

ST

AT-00219

(A) Toe side
(B) Heel side

MT-00652

(A)

(B)

MT-01401