DIFFERENTIALS
DI

DIFFERENTIALS > General Description
SPECIFICATION

Rear differential type | VA1
LSD type | —
Type of gear | Hypoid gear
Gear ratio |  | 3.700
Drive pinion bearing preload (for new bearing) | When measured with a spring scale (measured at the companion flange bolt hole) | N (kgf, lbf) | 12.7 — 32.2 (1.3 — 3.3, 2.9 — 7.2)
When measured with torque wrench | N·m (kgf-m, ft-lb) | 0.48 — 1.22 (0.05 — 0.12, 0.35 — 0.90)
Backlash between the differential bevel gear and differential bevel pinion | mm (in) | 0.05 — 0.15 (0.002 — 0.006)
Hypoid gear set backlash | mm (in) | 0.10 — 0.15 (0.004 — 0.006)
Companion flange mating surface runout | mm (in) | 0.08 (0.003)
Companion flange runout on its inner side | mm (in) | 0.08 (0.003)
Differential gear oil capacity | L (US qt, Imp qt) | 0.8 (0.85, 0.70)

Identification:

For identification, refer to “IDENTIFICATION”. IDENTIFICATION>MODEL NUMBER LABEL>REAR DIFFERENTIAL

Differential gear oil:

For the differential gear oil, refer to “RECOMMENDED MATERIALS”. RECOMMENDED MATERIALS>GREASE>DIFFERENTIAL GEAR OIL

DIFFERENTIALS > General Description
COMPONENT
1. REAR DIFFERENTIAL

(1) | Self-locking nut | (17) | Rear bearing outer race | (33) | Rear cover
(2) | Companion flange | (18) | Rear bearing inner race | (34) | Air breather cap
(3) | Differential front oil seal | (19) | Pinion height adjusting washer | (35) | Stud bolt
(4) | Pilot bearing | (20) | Hypoid gear set | (36) | Filler plug
(5) | Spacer | (21) | Drive pinion | (37) | Gasket
(6) | Front bearing | (22) | Driven gear | (38) | Drain plug
(7) | Front bearing inner race | (23) | Side bearing | (39) | Differential side retainer oil seal LH
(8) | Front bearing outer race | (24) | Side bearing outer race |  |
(9) | Differential carrier | (25) | Side bearing inner race | Tightening torque: N·m (kgf-m, ft-lb) |
(10) | Lock plate | (26) | Spring pin | T1: | 25 (2.5, 18.4)
(11) | O-ring | (27) | Pinion shaft | T2: | 50 (5.1, 36.9)
(12) | Differential side retainer | (28) | Differential case | T3: | DIFFERENTIALS>Rear Differential (VA-type)>ASSEMBLY
(13) | Differential side retainer oil seal RH | (29) | Thrust washer | T4: | DIFFERENTIALS>Rear Differential (VA-type)>ASSEMBLY
(14) | Preload adjusting washer | (30) | Differential bevel gear | T5: | DIFFERENTIALS>Rear Differential (VA-type)>ASSEMBLY
(15) | Preload adjusting spacer | (31) | Differential bevel pinion |  |
(16) | Rear bearing | (32) | Gasket |  |
∗: If the side bearing outer race is removed from the differential side retainer or the side bearing inner race is removed from the differential case, replace the side bearing with a new part.

2. REAR DIFFERENTIAL MOUNTING SYSTEM

(1) | Rear differential front member | (5) | Sub frame ASSY rear | Tightening torque: N·m (kgf-m, ft-lb)
(2) | Self-locking nut | (6) | Rear differential mount bushing | T: | DIFFERENTIALS>Rear Differential (VA-type)>INSTALLATION
(3) | Rear differential | (7) | Mass damper |  |
(4) | Rear differential member plate |  |  |  |

DIFFERENTIALS > General Description
CAUTION

- When performing service operation, refer to “Repair Contents” in “General Description”. REPAIR CONTENTS>Repair Contents

- Prior to starting work, pay special attention to the following:

  1. Always wear work clothes, a work cap, and protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary.

  2. Protect the vehicle using a seat cover, fender cover, etc.

  3. Prepare the service tools, clean cloth, containers to catch grease and oil, etc.

- Prevent scattering of grease and oil. If it scatters, wipe it off immediately to prevent it from penetrating the floor or flowing out, to protect the environmental.

- If the grease and oil is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

- Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.

- When performing a repair, identify the cause of trouble and avoid unnecessary work.

- Before disconnecting connectors of sensors or units, be sure to disconnect the ground terminal from the battery sensor.

- Always use the jack-up point when the lifting device, shop jacks or rigid racks are used to support the vehicle.

- Before starting works, remove dirt and corrosion around the target area.

- Keep the removed parts in order and protect them from dust and dirt.

- All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.

- For the parts except for the non-reusable parts, replace then with new parts if necessary.

- Be sure to tighten bolts and nuts to the specified torque.

- Always use new application oil during work.

DIFFERENTIALS > General Description
PREPARATION TOOL
1. SPECIAL TOOL

ILLUSTRATION | TOOL NUMBER | DESCRIPTION | REMARKS
| 398217700 | ATTACHMENT SET | Used for disassembly and assembly of differential carrier.
| 398477701 | HANDLE | Used for installing the front bearing outer race. Used together with DRIFT (498447110). Used for installing the rear bearing outer race. Used together with DRIFT (398477702).
| 398477702 | DRIFT | Used for installing the rear bearing outer race. Used together with HANDLE (398477701). Used for installing the side bearing outer race.
| 398507704 | BLOCK | Used for adjusting preload for front bearing and rear bearing. Used together with DUMMY SHAFT (498447150).
| 398527700 | PULLER ASSY | Used for removing the side bearing outer race.
| 399520105 | SEAT | Used for removing the side bearing inner race. Used together with PULLER SET (899524100).
| 399703600 | PULLER ASSY | Used for removing companion flange.
| 399780104 | WEIGHT | Used for installing the front bearing inner race, pilot bearing, differential front oil seal and companion flange.
| 498077400 | REMOVER | Used for removing the rear bearing inner race and pinion height adjusting washer.
| 498175500 | INSTALLER | Used for installing the rear bearing inner race.
| 498427200 | FLANGE WRENCH | Used for removing and installing the self-locking nut of companion flange. Used for adjusting hypoid gear set backlash. Used for adjusting preload on the side bearing.
| 498447100 | INSTALLER | Used for installing the differential side retainer oil seal.
| 498447110 | DRIFT | Used for installing the front bearing outer race. Used together with HANDLE (398477701).
| 498447120 | INSTALLER | Used for installing the differential front oil seal.
| 498447150 | DUMMY SHAFT | Used for adjusting preload for front bearing and rear bearing. Used together with BLOCK (398507704). Used for adjusting drive pinion height. Used together with DIFFERENTIAL CARRIER GAUGE (498505501).
| 498485400 | DRIFT | Used for installing the side bearing inner race.
| 498505501 | DIFFERENTIAL CARRIER GAUGE | Used for adjusting drive pinion height.
| 899524100 | PULLER SET | Used for removing the side bearing inner race. (1) Puller (2) Cap Used together with SEAT (399520105).
| 899580100 | INSTALLER | Used for installing the front bearing inner race.
| 899874100 | INSTALLER | Used for installing the companion flange.
| 899904100 | STRAIGHT PIN REMOVER | Used for removing and installing the spring pin.
| 18270KA020 | SOCKET (E20) | Used for removing and installing the driven gear.
| 18658AA021 | WRENCH COMPL RETAINER | Used for removing and installing the differential side retainer.
| 28099PA090 | OIL SEAL PROTECTOR | Used for installing the rear drive shaft. (For oil seal protection)
| 41399FG001 | SPECIAL TOOL ASSY | Used for removing and installing the rear differential mount bushing. Apply the molybdenum grease on the threads. Use (1), (2), (5), (6), (7), (8) and (9) for removal. Use (3), (4), (5), (6), (7), (8) and (9) for installation. (1) SPECIAL TOOL A (41399FG010) (2) SPECIAL TOOL C (41399FG031) (3) SPECIAL TOOL B (41399FG020) (4) SPECIAL TOOL D (41399FG041) (5) SPECIAL TOOL SLEEVE (41399FG050) (6) SPECIAL TOOL RING (41399FG061) (7) SPECIAL TOOL NUT (41399FG070) (8) SPECIAL TOOL BEARING (41399FG080) (9) SPECIAL TOOL SHAFT (41399FG091)
| 41399FG010 | SPECIAL TOOL A | Used for removing the rear differential mount bushing. For combination of tools, refer to “SPECIAL TOOL ASSY (41399FG001)”.
| 41399FG020 | SPECIAL TOOL B | Used for installing the rear differential mount bushing. For combination of tools, refer to “SPECIAL TOOL ASSY (41399FG001)”.
| 41399FG031 | SPECIAL TOOL C | Used for removing the rear differential mount bushing. For combination of tools, refer to “SPECIAL TOOL ASSY (41399FG001)”.
| 41399FG041 | SPECIAL TOOL D | Used for installing the rear differential mount bushing. For combination of tools, refer to “SPECIAL TOOL ASSY (41399FG001)”.
| 41399FG050 | SPECIAL TOOL SLEEVE | Used for removing and installing the rear differential mount bushing. For combination of tools, refer to “SPECIAL TOOL ASSY (41399FG001)”.
| 41399FG061 | SPECIAL TOOL RING | Used for removing and installing the rear differential mount bushing. For combination of tools, refer to “SPECIAL TOOL ASSY (41399FG001)”.
| 41399FG070 | SPECIAL TOOL NUT | Used for removing and installing the rear differential mount bushing. For combination of tools, refer to “SPECIAL TOOL ASSY (41399FG001)”.
| 41399FG080 | SPECIAL TOOL BEARING | Used for removing and installing the rear differential mount bushing. For combination of tools, refer to “SPECIAL TOOL ASSY (41399FG001)”.
| 41399FG091 | SPECIAL TOOL SHAFT | Used for removing and installing the rear differential mount bushing. For combination of tools, refer to “SPECIAL TOOL ASSY (41399FG001)”.
| — | SUBARU SELECT MONITOR 4 | Used for setting of each function and troubleshooting for electrical system. For detailed operation procedures, refer to “Help” of application.

2. GENERAL TOOL

TOOL NAME | REMARKS
Transmission jack | Used for removing and installing the rear differential.
Thickness gauge | Used for various inspections.
Spring scale | Used for measuring the initial load.
Crowbar | Used for removing the rear drive shaft.
Angle gauge | Used for angle tightening.
Dial gauge | Used for measuring backlash.
Magnet stand | Used for measuring backlash.
DST-i | Used together with Subaru Select Monitor 4.

DIFFERENTIALS > Differential Gear Oil
INSPECTION

If the differential gear oil is spilt over exhaust pipe, etc., wipe it off to avoid emitting smoke or causing a fire.

1.

Remove the filler plug (A).

2.

Check the differential gear oil.

Replace the differential gear oil if it is degraded, clouded or contaminated. DIFFERENTIALS>Differential Gear Oil>REPLACEMENT

3.

Check that the differential gear oil level is within −5 mm (−0.2 in) from the bottom of the filler plug hole.

If the differential gear oil level is low, make sure that there is no oil leakage and refill up to the bottom of filler plug hole.

- Only at factory settings, the oil level is normal if it is within −14 mm (−0.6 in) from the bottom of the filler plug.

- Fill the differential gear oil until it flow out of the filler plug hole and wait the outflow to stop.

Differential gear oil:

For the differential gear oil, refer to “RECOMMENDED MATERIALS”. RECOMMENDED MATERIALS>GREASE>DIFFERENTIAL GEAR OIL

4.

Using a new gasket, install the filler plug (A).

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

DIFFERENTIALS > Differential Gear Oil
REPLACEMENT

If the differential gear oil is spilt over exhaust pipe, etc., wipe it off to avoid emitting smoke or causing a fire.

1.

Remove the filler plug and drain plug, and drain differential gear oil.

2.

Remove the iron powder, etc. from the drain plug.

3.

Install the drain plug using a new gasket.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

4.

Fill the differential gear oil to the bottom of filler plug hole.

Fill the differential gear oil until it flow out of the filler plug hole and wait the outflow to stop.

Differential gear oil:

For the differential gear oil, refer to “RECOMMENDED MATERIALS”. RECOMMENDED MATERIALS>GREASE>DIFFERENTIAL GEAR OIL

Differential gear oil capacity:

For the differential gear oil capacity, refer to “SPECIFICATIONS”. DIFFERENTIALS>General Description>SPECIFICATION

5.

Using a new gasket, install the filler plug.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

DIFFERENTIALS > Front Differential
NOTE

For the front differential, refer to the “CONTINUOUSLY VARIABLE TRANSMISSION”. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Front Differential

DIFFERENTIALS > Rear Differential (VA-type)
REMOVAL
1.

Release the parking brake.

2.

Release the shift lock using a screwdriver, etc. and shift the select lever to the “N” range.

3.

Drain differential gear oil. DIFFERENTIALS>Differential Gear Oil>REPLACEMENT

4.

Remove the propeller shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>REMOVAL

5.

Loosen the self-lock nuts securing the mass damper and rear differential.

Do not over-loosen the self-locking nut because the rear differential may fall off.

6.

Using a crowbar, etc., disengage the rear drive shaft (RH) and rear drive shaft (LH).

Crowbar, etc. must keep in contact with the bolt (a) securing the lock plate.

7.

Set the transmission jack.

8.

Remove the rear differential front member.

9.

Remove the self-locking nut and remove the mass damper.

10.

Pull out the stud bolt from the rear differential mount bushing.

Adjust the position and angle of the transmission jack if necessary.

11.

Lower the transmission jack, pull out the rear drive shaft and remove the rear differential.

If the circlip remains inside the rear differential, overhaul the differential case.

12.

Hang the rear drive shaft with a string, etc.

This is necessary to prevent damage of the rear drive shaft.

13.

Remove the rear differential member plate.

DIFFERENTIALS > Rear Differential (VA-type)
INSTALLATION

Use a rear differential as specified.

1.

Replace with a new differential side retainer oil seal. DIFFERENTIALS>Differential Side Retainer Oil Seal>REPLACEMENT

2.

Set the rear differential member plate.

3.

Set the rear differential to transmission jack.

4.

Apply differential gear oil to the differential side retainer oil seal lip and rear drive shaft insertion section.

5.

Set the ST to differential side retainer.

Preparation tool:

ST: OIL SEAL PROTECTOR (28099PA090)

6.

Insert the splines of the rear drive shaft into the rear differential, and remove the ST (OIL SEAL PROTECTOR).

Remove the ST before inserting the rear drive shaft completely.

7.

Insert the rear drive shaft completely.

8.

Insert the stud bolt into the rear differential mount bushing.

Adjust the position and angle of the transmission jack if necessary.

9.

Set the mass damper to the stud bolt and temporarily install the self-locking nut.

Be sure to use a new self-locking nut.

10.

Temporarily install the rear differential front member.

Be sure to use a new self-locking nut.

11.

Detach the transmission jack, and tighten the self-locking nut.

Be sure to detach the transmission jack, and tighten the self-locking nut with the rear differential seated under its own weight.

Tightening torque:

T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

T2: 70 N·m (7.1 kgf-m, 51.6 ft-lb)

T3: 110 N·m (11.2 kgf-m, 81.1 ft-lb)

12.

Install the propeller shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>INSTALLATION

13.

Fill differential gear oil. DIFFERENTIALS>Differential Gear Oil>REPLACEMENT

14.

Shift the select lever to “P range”.

15.

Apply the parking brake.

16.

When the rear differential or hypoid gear set is replaced, perform “Rear differential inspection mode” using the Subaru Select Monitor. DIFFERENTIALS>Rear Differential Inspection Mode

DIFFERENTIALS > Rear Differential (VA-type)
DISASSEMBLY
1.

Set the ST on vise and install the rear differential.

Preparation tool:

ST: ATTACHMENT SET (398217700)

2.

Remove the stud bolt from the rear cover.

Perform this procedure only when required.

3.

Remove the air breather cap.

Perform this procedure only when required.

4.

Remove the bolts, and remove the rear cover while lightly tapping with a plastic hammer.

5.

Measure and record the tooth contact and backlash of hypoid gear set. DIFFERENTIALS>Rear Differential (VA-type)>ASSEMBLY

6.

Remove the differential side retainer oil seal using a flat tip screwdriver wrapped with protection tape, etc.

7.

Remove the lock plate.

8.

Remove the differential side retainer using the ST.

- Be careful not to drop the differential case.

- Be careful not to hit the teeth of driven gear against the differential carrier.

When there is no replacement of side bearing, do not confuse the left and right side.

Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA021)

9.

Remove the differential case.

Be careful not to hit the teeth of driven gear against the differential carrier.

10.

Remove the side bearing outer race using the ST.

Perform this procedure only when required.

Preparation tool:

ST: PULLER ASSY (398527700)

11.

Remove the O-ring from the differential side retainer.

12.

Remove the side bearing inner race using ST1 and ST2.

Perform this procedure only when required.

Preparation tool:

ST1: PULLER SET (899524100)

ST2: SEAT (399520105)

13.

Remove the driven gear from the differential case using the ST.

Preparation tool:

ST: SOCKET (E20) (18270KA020)

14.

Using the ST, remove the spring pin.

Preparation tool:

ST: STRAIGHT PIN REMOVER (899904100)

15.

Pull out the pinion shaft, and remove the differential bevel pinion, differential bevel gear and thrust washer.

If each part is reused, do not confuse the installation position.

(A) | Pinion shaft | (C) | Differential bevel gear | (D) | Thrust washer
(B) | Differential bevel pinion |  |  |  |

16.

Remove the self-locking nut while securing the companion flange with ST.

Preparation tool:

ST: FLANGE WRENCH (498427200)

17.

Extract the companion flange using the ST.

Preparation tool:

ST: PULLER ASSY (399703600)

18.

Remove the differential front oil seal using a flat tip screwdriver wrapped with protection tape, etc.

19.

Remove seal material from the thread portions of the companion flange and drive pinion.

20.

Remove the rear differential from ST.

21.

Press the end of drive pinion using the press, and remove the drive pinion, pinion height adjusting washer, rear bearing inner race, preload adjusting spacer and preload adjusting washer as a set.

Be careful not to drop the drive pinion.

22.

Remove the pilot bearing, spacer and front bearing inner race from the differential carrier.

(A) | Pilot bearing | (B) | Spacer | (C) | Front bearing inner race

23.

Remove the drive pinion from the rear bearing inner race using the ST and a press.

Be careful not to drop the drive pinion.

Preparation tool:

ST: REMOVER (498077400)

24.

Measure and record the thickness of the pinion height adjusting washer.

25.

Tap out and remove the front bearing outer race and rear bearing outer race using a brass bar.

- Remove the front bearing outer race first.

- Tap out the rear bearing outer race from the front side to remove.

- Using the indentation (a) on the differential carrier, tap out the two points alternately to remove.

DIFFERENTIALS > Rear Differential (VA-type)
ASSEMBLY
1.

Adjusting preload for front bearing and rear bearing

The adjustment must be carried out with the differential front oil seal removed.

(1)

Press-fit the new rear bearing outer race (A) using the ST1, ST2 and press.

Apply the differential gear oil to the rear bearing outer race.

Preparation tool:

ST1: HANDLE (398477701)

ST2: DRIFT (398477702)

(2)

Press-fit the new front bearing outer race (A) using the ST1, ST2 and press.

Apply the differential gear oil to the front bearing outer race.

Preparation tool:

ST1: HANDLE (398477701)

ST2: DRIFT (498447110)

(3)

Select the thickness of pinion height adjusting washer based on the backlash, tooth contact and pinion height adjusting washer thickness of the hypoid gear set measured when disassembling.

In the inspection before disassembly, if the backlash and tooth contact of the hypoid gear set are normal, check that the pinion height adjusting washer is not deformed or damaged to reuse it.

(4)

Set the selected pinion height adjusting washer, new rear bearing inner race, preload adjusting spacer and preload adjusting washer on the ST and insert them in the differential carrier.

Apply the differential gear oil to the rear bearing inner race.

Preparation tool:

ST: DUMMY SHAFT (498447150)

(A) | Pinion height adjusting washer | (C) | Preload adjusting spacer | (E) | Differential carrier
(B) | Rear bearing inner race | (D) | Preload adjusting washer |  |

(5)

Set a new front bearing inner race, spacer, and a new pilot bearing.

Apply the differential gear oil to the front bearing inner race and the pilot bearing.

(A) | Front bearing inner race | (B) | Spacer | (C) | Pilot bearing

(6)

Set the companion flange and temporarily install the self-locking nut.

- Use the self-locking nut removed when disassembling.

- Do not install the differential front oil seal.

(A) | Companion flange | (B) | Self-locking nut |  |

(7)

Set the ST on vise and install the rear differential.

Preparation tool:

ST: ATTACHMENT SET (398217700)

(8)

Turn the companion flange by hand to smooth each bearing.

(9)

Tighten the self-locking nut while measuring the initial torque or initial load torque with a torque wrench or spring scale.

If the initial torque or the initial load exceeds the specification before the tightening torque reaches the specified value, immediately stop the tightening.

- When tightening the self-locking nut, secure the ST1 with the ST2 as shown in the figure.

- When tightening with specified torque, select the preload adjusting washer and the preload adjusting spacer so that the initial torque or the initial load is within the specification.

Preparation tool:

ST1: DUMMY SHAFT (498447150)

ST2: BLOCK (398507704)

Specified torque:

191 N·m (19.5 kgf-m, 140.9 ft-lb)

Specification:

Initial torque

0.48 — 1.22 N·m (0.05 — 0.12 kgf-m, 0.35 — 0.90 ft-lb)

Initial load

12.7 — 32.2 N (1.3 — 3.3 kgf, 2.9 — 7.2 lbf)

(10)

Record the initial torque or initial load after preload adjustment.

2.

Adjusting drive pinion height:

(1)

Set the ST.

Preparation tool:

ST: DIFFERENTIAL CARRIER GAUGE (498505501)

(A) | Front side | (B) | RH side

(2)

Measure the clearance “C” between the ST1 and ST2 by using a thickness gauge.

Make sure there is no clearance between the differential carrier and ST2.

Preparation tool:

ST1: DUMMY SHAFT (498447150)

ST2: DIFFERENTIAL CARRIER GAUGE (498505501)

(A) | Front side | (B) | RH side |  |

(3)

Calculate an appropriate pinion height adjusting washer using the following calculation.

Use the pinion height adjusting washer within the range of 1 — 3.

T = To + C − 0.05 mm (0.0020 in)

T | Thickness of pinion height adjusting washer mm (in)
To | Thickness of washer temporarily inserted mm (in)
C | Clearance of thickness gauge mm (in)

3.

Remove the self-locking nut and the companion flange.

(A) | Companion flange | (B) | Self-locking nut |  |

4.

Remove the ST1, ST2 and each part from differential carrier.

Preparation tool:

ST1: DIFFERENTIAL CARRIER GAUGE (498505501)

ST2: DUMMY SHAFT (498447150)

5.

Remove the rear differential from ST.

Preparation tool:

ST: ATTACHMENT SET (398217700)

6.

Remove the pilot bearing, spacer and front bearing inner race from the differential carrier.

(A) | Pilot bearing | (B) | Spacer | (C) | Front bearing inner race

7.

Set the pinion height adjusting washer with a calculated thickness to the drive pinion.

8.

Press-fit the rear bearing inner race to the drive pinion using the ST and a press.

Apply the differential gear oil to the rear bearing inner race.

Preparation tool:

ST: INSTALLER (498175500)

9.

Set the preload adjusting spacer and preload adjusting washer on the drive pinion, and insert them in the differential carrier.

(A) | Drive pinion | (C) | Preload adjusting washer | (D) | Differential carrier
(B) | Preload adjusting spacer |  |  |  |

10.

Set the ST and rear differential carrier to the press.

Leave the ST and differential carrier set on the press until the companion flange is press-fitted.

Preparation tool:

ST: WEIGHT (399780104)

11.

Press-fit the front bearing inner race (A) using the ST, spacer (B) and press.

- Apply the differential gear oil to the front bearing inner race.

- Leave the spacer as being set.

Preparation tool:

ST: INSTALLER (899580100)

12.

Install the pilot bearing.

Apply the differential gear oil to the pilot bearing.

13.

Install the new differential front oil seal using the ST and press.

- Press-fit the differential front oil seal so that it comes 1 mm (0.04 in) inward from end of carrier.

- Apply differential gear oil to the differential front oil seal lip.

Preparation tool:

ST: INSTALLER (498447120)

14.

Press-fit the companion flange with ST and press.

Be careful not to damage the pilot bearing.

Preparation tool:

ST: INSTALLER (899874100)

15.

Attach the rear differential to the ST.

Preparation tool:

ST: ATTACHMENT SET (398217700)

16.

Apply seal material to the drive pinion threads and the self-locking nut seat surface.

Be sure to use a new self-locking nut.

Before applying the seal material, degrease the contact surfaces of the self locking nut and companion flange and the thread portions of the chain cover.

Seal material:

THREE BOND 1324 (Part No. 004403042) or equivalent

17.

Install the self-locking nut while securing the companion flange with the ST.

Tighten it while adjusting within the specified torque so that the companion flange initial torque or initial load becomes within the specification.

Specification:

Initial torque

0.48 — 1.22 N·m (0.05 — 0.12 kgf-m, 0.35 — 0.90 ft-lb)

Initial load

12.7 — 32.2 N (1.3 — 3.3 kgf, 2.9 — 7.2 lbf)

Preparation tool:

ST: FLANGE WRENCH (498427200)

Tightening torque:

162 — 220 N·m (16.5 — 22.5 kgf-m, 119.5 — 162.3 ft-lb)

18.

Assembling differential case

(1)

Check that oil grooves of differential bevel gears RH and LH face in the same direction.

When replacing the differential bevel gear, replace both RH and LH as a set.

There are 2 types of side gear oil groove directions.

(A) | Type A | (B) | Type B |

(2)

Set the differential bevel pinion, differential bevel gear and thrust washer, and install the pinion shaft.

- Apply differential gear oil on the sliding portion of the differential bevel gear, thrust washer and pinion shaft.

- Install the thrust washer with its chamfered side facing the differential bevel gear.

(A) | Pinion shaft | (C) | Differential bevel gear | (D) | Thrust washer
(B) | Differential bevel pinion |  |  |  |

(3)

Measure the backlash between the differential bevel gear and differential bevel pinion using the magnet stand and dial gauge.

If it exceeds the standard value, select the thrust washers so that the backlash is within the standard.

Specification:

0.05 — 0.15 mm (0.002 — 0.006 in)

(4)

Rotate each gear by hand, and check that it moves smoothly.

(5)

Using the ST, install a new spring pin.

Preparation tool:

ST: STRAIGHT PIN REMOVER (899904100)

19.

Install the driven gear to the differential case.

(1)

Using the ST, tighten the bolts in the numerical order as shown in the figure.

Make sure there is no clearance between the differential case and driven gear.

Preparation tool:

ST: SOCKET (E20) (18270KA020)

Tightening torque:

20 N·m (2.0 kgf-m, 14.8 ft-lb)

(2)

Using angle gauge, further tighten the bolts in numerical order as shown in the figure.

Tightening angle:

46°

20.

Press-fit a new side bearing inner race using the ST and a press.

Apply the differential gear oil to the side bearing inner race.

Preparation tool:

ST: DRIFT (498485400)

21.

Assemble the differential side retainer.

(1)

Install a new side bearing outer race using the ST and a press.

Apply the differential gear oil to the side bearing outer race.

Preparation tool:

ST: DRIFT (398477702)

(2)

Install the new differential side retainer oil seal.

Since the differential side retainer oil seal has an identification mark (R or L), be careful not to mix up the RH and LH when installing.

Preparation tool:

ST: INSTALLER (498447100)

22.

Set the differential case.

- Be careful not to drop the differential carrier.

- Be careful not to hit the teeth of driven gear against the differential carrier.

23.

Temporarily install the differential side retainer.

- Be careful not to drop the differential carrier.

- Be careful not to hit the teeth of driven gear against the differential carrier.

- When the side bearing is reused, do not confuse the left and right side.

- Apply differential gear oil to the threads of the side bearing and the differential side retainer.

- Do not install the O-ring.

24.

Backlash adjustment of hypoid gear set and preload adjustment of side bearing

(1)

Turn the drive pinion with the ST to seat the side bearing securely.

Preparation tool:

ST: FLANGE WRENCH (498427200)

(2)

Using the ST, tighten differential side retainer (RH side), and then tighten differential side retainer (LH side) until there is no backlash.

Be careful not to overtighten.

Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA021)

(3)

Return the differential side retainer LH by 1.5 notches, and tighten the differential side retainer RH by 2 notches.

This sets the preload.

(4)

Temporarily attach the lock plate.

Turn over the lock plate to shift by 0.5 teeth if the lock plate does not align with the teeth.

(5)

Using a magnet stand and dial gauge, measure the backlash of hypoid gear set.

If it is outside the specification, repeat the procedures for the backlash adjustment of the hypoid gear set and preload adjustment of the side bearing.

Specification:

0.10 — 0.15 mm (0.004 — 0.006 in)

25.

Checking and adjusting the tooth contact of hypoid gear set

(1)

Apply lead-free red dye evenly on the three to four teeth of the driven gear.

(2)

Check the contact pattern by rotating the driven gear back and forth several times until a definite contact pattern appears on the driven gear.

- If proper tooth contact is not obtained, readjust the backlash of hypoid gear set and drive pinion height.

- Wipe off the lead-free red dye completely after the check and adjustment are completed.

1. Correct tooth contact

   Tooth contact pattern is slightly shifted toward toe side under no-load rotation. (When driving, it moves towards the heel side.)

   (A) | Toe side (inside) | (B) | Heel side (outside)

2. Face contact

   Cause: Excessive backlash

   Adjustment: Loosen the differential side retainer RH, and tighten the differential side retainer LH by the same amount.

   Or, adjust the pinion height adjusting washer thickness to move the drive pinion toward the driven gear side.

3. Flank contact

   Cause: Too small backlash

   Adjustment: Loosen the differential side retainer LH, and tighten the differential side retainer RH by the same amount.

   Or, adjust the pinion height adjusting washer thickness to separate the drive pinion from the driven gear.

4. Toe contact (inside contact)

   Cause: Teeth contact area is too small.

   Adjustment: Adjust the pinion height adjusting washer thickness and separate the drive pinion from the driven gear.

5. Heel contact (outside end contact)

   Cause: Teeth contact area is too small.

   Adjustment: Adjust the pinion height adjusting washer thickness and move the drive pinion to the driven gear side.

26.

Put alignment marks (A) on the differential carrier and the differential side retainer.

27.

Remove the differential side retainers one by one and install new O-rings.

Apply differential gear oil to the threads of the side bearing and the differential side retainer, and to the O-ring.

28.

Return the differential side retainer to the original tightening position and install the lock plate.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

29.

Using a magnet stand and dial gauge, recheck the backlash of hypoid gear set.

Specification:

0.10 — 0.15 mm (0.004 — 0.006 in)

30.

Using a new gasket, install the rear cover.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

31.

Install the stud bolt so that the protruding portion (A) becomes within the standard.

Do not tighten with a tightening torque of 55 N·m (5.6 kg-m, 40.6 ft-lb) (reference value) or more.

Specification:

59.0 — 61.0 mm (2.32 — 2.40 in)

32.

Install the air breather cap by tapping the section (A).

DIFFERENTIALS > Rear Differential (VA-type)
INSPECTION

- For backlash between the differential bevel gear and differential bevel pinion, refer to “ASSEMBLY”. DIFFERENTIALS>Rear Differential (VA-type)>ASSEMBLY

- For backlash and tooth contact of hypoid gear set, refer to “ASSEMBLY”. DIFFERENTIALS>Rear Differential (VA-type)>ASSEMBLY

1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

3.

Check each part for excessive wear.

4.

Check the differential carrier and companion flange for excessive rust.

5.

Check the companion flange runout.

(1)

Remove the foreign matter and rust completely from the companion flange.

(2)

Measure the runout of the companion flange mating surface using a magnet stand and dial gauge.

Service limit:

0.08 mm (0.003 in)

(3)

Measure the runout inside the companion flange using a magnet stand and dial gauge.

Service limit:

0.08 mm (0.003 in)

(4)

If either runout exceeds the limit, move the phase of companion flange and drive pinion by 90° each, and find the point where the runout is within the limit.

If the runout exceeds the limit after changing the phase, replace the companion flange and recheck the runout.

If the runout exceeds the limit after replacing the companion flange, the drive pinion or bearing may be defective.

DIFFERENTIALS > Differential Front Oil Seal
REPLACEMENT
1.

Release the parking brake.

2.

Release the shift lock using a screwdriver, etc. and shift the select lever to the “N” range.

3.

Drain differential gear oil. DIFFERENTIALS>Differential Gear Oil>REPLACEMENT

4.

Remove the propeller shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>REMOVAL

5.

Measure and record the initial torque or initial load before removing the companion flange.

6.

Remove the self-locking nut while securing the companion flange with ST.

Preparation tool:

ST: FLANGE WRENCH (498427200)

7.

Extract the companion flange using the ST.

Preparation tool:

ST: PULLER ASSY (399703600)

8.

Remove the differential front oil seal using a flat tip screwdriver wrapped with protection tape, etc.

9.

Remove seal material from the thread portions of the companion flange and drive pinion.

10.

Install the new differential front oil seal using the ST.

- Press-fit the differential front oil seal so that it comes 1.0 mm (0.04 in) inward from end of the differential carrier.

- After installation, apply differential gear oil to the differential front oil seal lip.

Preparation tool:

ST: INSTALLER (498447120)

11.

Use a plastic hammer, etc. to install companion flange.

12.

Apply seal material to the drive pinion threads and the self-locking nut seat surface.

Be sure to use a new self-locking nut.

Before applying the seal material, degrease the contact surfaces of the self locking nut and companion flange and the thread portions of the chain cover.

Seal material:

THREE BOND 1324 (Part No. 004403042) or equivalent

13.

Install the self-locking nut while securing the companion flange with the ST.

Tighten it while adjusting within the specified tightening torque so that the companion flange initial torque or initial load becomes the same as before replacing the differential front oil seal.

Preparation tool:

ST: FLANGE WRENCH (498427200)

Tightening torque:

162 — 220 N·m (16.5 — 22.5 kgf-m, 119.5 — 162.3 ft-lb)

14.

Install the propeller shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>INSTALLATION

15.

Fill differential gear oil. DIFFERENTIALS>Differential Gear Oil>REPLACEMENT

16.

Shift the select lever to “P range”.

17.

Apply the parking brake.

DIFFERENTIALS > Differential Front Oil Seal
INSPECTION
1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

DIFFERENTIALS > Differential Side Retainer Oil Seal
REPLACEMENT
1.

Release the parking brake.

2.

Release the shift lock using a screwdriver, etc. and shift the select lever to the “N” range.

3.

Drain differential gear oil. DIFFERENTIALS>Differential Gear Oil>REPLACEMENT

4.

Remove the rear differential. DIFFERENTIALS>Rear Differential (VA-type)>REMOVAL

5.

Remove the differential side retainer oil seal using a flat tip screwdriver wrapped with protection tape, etc.

6.

Install the new differential side retainer oil seal using the ST.

Since the differential side retainer oil seal has an identification mark (R or L), be careful not to mix up the RH and LH when installing.

Preparation tool:

ST: INSTALLER (498447100)

7.

Install the rear differential. DIFFERENTIALS>Rear Differential (VA-type)>INSTALLATION

Apply differential gear oil to the differential side retainer oil seal lip and rear drive shaft insertion section.

8.

Fill differential gear oil. DIFFERENTIALS>Differential Gear Oil>REPLACEMENT

9.

Shift the select lever to “P range”.

10.

Apply the parking brake.

DIFFERENTIALS > Differential Side Retainer Oil Seal
INSPECTION
1.

Check for oil leaks.

2.

Check that there is no deformation, cracks or other damages.

DIFFERENTIALS > Rear Differential Front Member
REMOVAL
1.

Set the transmission jack to the rear differential.

2.

Remove the rear differential front member.

DIFFERENTIALS > Rear Differential Front Member
INSTALLATION
1.

Temporarily install the rear differential front member.

Be sure to use a new self-locking nut.

2.

Detach the transmission jack, and tighten the self-locking nut.

Be sure to detach the transmission jack, and tighten the self-locking nut with the rear differential seated under its own weight.

Tightening torque:

T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

T2: 110 N·m (11.2 kgf-m, 81.1 ft-lb)

DIFFERENTIALS > Rear Differential Front Member
INSPECTION
1.

Check that there is no deformation, cracks or other damages.

2.

Check for excessive rusting.

3.

Check the bushing for crack or excessive hardening.

DIFFERENTIALS > Rear Differential Mount Bushing
REPLACEMENT

Be sure to remove dirt and rust before work.

1.

Remove the rear differential. DIFFERENTIALS>Rear Differential (VA-type)>REMOVAL

2.

Fit the ST to the periphery of the sub frame cylinder, and make sure that the ST does not contact with welded spots (A) or spatters.

If the ST rises on the welded spots (A) or spatters, the ST may be damaged during the operation. To avoid this, grind the excessive welds or spatters with a sander or equivalent so that the ST contacts the cylinder peripheral part.

Preparation tool:

ST: SPECIAL TOOL A (41399FG010)

3.

Set the ST1, ST2, ST3, ST4 and ST5 as shown in the figure.

Apply the molybdenum grease on the thread of the ST.

Preparation tool:

ST1: SPECIAL TOOL SHAFT (41399FG091)

ST2: SPECIAL TOOL NUT (41399FG070)

ST3: SPECIAL TOOL SLEEVE (41399FG050)

ST4: SPECIAL TOOL BEARING (41399FG080)

ST5: SPECIAL TOOL A (41399FG010)

(A) | 5 mm (0.2 in) or less

4.

Set the ST1 and ST2 in the rear side of the rear differential mount bushing, and hold them.

Preparation tool:

ST1: SPECIAL TOOL C (41399FG031)

ST2: SPECIAL TOOL RING (41399FG061)

(A) | Front side

5.

Insert the ST set in the step 3 through the rear differential mount bushing hole from the front side, and screw in the ST1 by hand till the front end of ST1 comes out from the rear end of ST2 by approx. 3.0 mm (0.12 in).

Preparation tool:

ST1: SPECIAL TOOL SHAFT (41399FG091)

ST2: SPECIAL TOOL RING (41399FG061)

6.

Hold the ST1 to prevent it from rotating, and screw in the ST3 by hand till there is no loose fit on the ST2.

- Check that the ST2 contacts the cylinder circumference of the sub frame.

- Check that the ST is not tilted.

Preparation tool:

ST1: SPECIAL TOOL SHAFT (41399FG091)

ST2: SPECIAL TOOL A (41399FG010)

ST3: SPECIAL TOOL NUT (41399FG070)

7.

Hold the ST1 with a tool to prevent it from rotating, and screw in the ST2 to remove the rear differential mount bushing.

- Rotation of ST1 will damage the ST. Never rotate the ST1.

- If the ST starts to tilt, stop the work and set the ST again.

Preparation tool:

ST1: SPECIAL TOOL SHAFT (41399FG091)

ST2: SPECIAL TOOL NUT (41399FG070)

8.

Set the ST1, ST2, ST3, ST4, ST5 and rear differential mount bushing as shown in the figure.

Apply the molybdenum grease on the thread of the ST.

- Set the ST2 nut near to the end of ST1 screw.

- Hold the rear differential mount bushing with the arrow marked side facing toward the rear side, and set the arrow mark facing upward.

- Mark the bottom end of rear differential mount bushing to identify the installing direction.

Preparation tool:

ST1: SPECIAL TOOL SHAFT (41399FG091)

ST2: SPECIAL TOOL NUT (41399FG070)

ST3: SPECIAL TOOL SLEEVE (41399FG050)

ST4: SPECIAL TOOL BEARING (41399FG080)

ST5: SPECIAL TOOL B (41399FG020)

(A) | Front side | (C) | 8 mm (0.31 in) or more | (E) | Arrow mark
(B) | Upside | (D) | Marked position |  |

9.

Set the ST1 and ST2 in the rear side of the sub frame assembly rear, and hold them.

Preparation tool:

ST1: SPECIAL TOOL D (41399FG041)

ST2: SPECIAL TOOL RING (41399FG061)

10.

Insert the ST and rear differential mount bushing set in the step 8 through the sub frame from the front side, and screw in the ST2 by hand till the front end of ST2 comes out from the rear end of ST1 by approx. 3.0 mm (0.12 in).

Set the rear differential mount bushing with its mark (a) facing the bottom end direction.

Preparation tool:

ST1: SPECIAL TOOL SHAFT (41399FG091)

ST2: SPECIAL TOOL RING (41399FG061)

11.

Hold the ST1 to prevent it from rotating, and screw in the ST2 by hand till there is no loose fit on the ST and the rear differential mount bushing.

Make sure that the ST and rear differential mount bushing are not tilted.

Preparation tool:

ST1: SPECIAL TOOL SHAFT (41399FG091)

ST2: SPECIAL TOOL NUT (41399FG070)

12.

Screw in the ST2 while holding the ST1 with a tool to prevent it from rotating, and press-fit the rear differential mount bushing to the front end of sub frame cylinder.

- Rotation of ST1 will damage the ST. Never rotate the ST1.

- If the ST starts to tilt, stop the work and set the ST again.

Preparation tool:

ST1: SPECIAL TOOL SHAFT (41399FG091)

ST2: SPECIAL TOOL NUT (41399FG070)

13.

Make sure that the rear differential mount bushing is inserted to the front end of sub frame cylinder.

(A) | Front side

14.

Install the rear differential. DIFFERENTIALS>Rear Differential (VA-type)>INSTALLATION

Apply differential gear oil to the differential side retainer oil seal lip and rear drive shaft insertion section.

DIFFERENTIALS > Rear Differential Mount Bushing
INSPECTION
1.

Check that there is no deformation, cracks or other damages.

2.

Check the bushing for crack or excessive hardening.

DIFFERENTIALS > Rear Differential Inspection Mode
PROCEDURE

- When replacing transmission main body, front differential hypoid gear set, transfer driven gear, rear differential, rear differential hypoid gear set, perform rear differential inspection mode.

- Do not turn the power of the Subaru Select Monitor OFF during work, and do not disconnect the data link connector.

1.

Shift the select lever to “P range”.

2.

Apply the parking brake.

3.

Lift up the vehicle.

- Lift up the vehicle until the tire bottom is 0.3 m (0.98 ft) or more above the ground.

- Make sure that safety is secured where the tiers rotate.

4.

Connect the Subaru Select Monitor.

5.

Turn the ignition switch to ON. (Engine OFF)

6.

On [Start] screen, select [Diagnosis].

7.

On [Vehicle selection] screen, enter vehicle information and select [Set].

8.

On [Main Menu] screen, select [Each System].

9.

On [Select System] screen, select [Transmission Control System].

10.

On [Select Function] screen, select [Work Support].

11.

On [Work Support] screen, select [Rear differential inspection mode].

12.

Follow the messages displayed on the screen when working.

13.

The results of the rear differential inspection mode are displayed on the screen.

- When ended normally:

  [The rear differential has been replaced normally. Front-rear rotation ratio &STR01]

- When ended abnormally:

  [A rear differential abnormality has been detected. Reinspect the items at the time of rear differential installation. Front-rear rotation ratio &STR01]

- When interrupted:

  [Inspection is stopped. Restart this inspection mode from the beginning.]

14.

When [Please be IGOFF in a safe state] appears, the rear differential inspection mode completes.

- When the rear differential inspection mode is completed properly, the warning light of VDC, ABS, engine, power steering or EyeSight may illuminate. But this is not a malfunction.

  If warning light illuminates, clear the memory.

- If the rear differential inspection mode does not end normally, repeat the mode until it ends normally.

- When the inspection mode does not end normally, the AWD warning light will start blinking at 2 Hz.

- When the rear differential inspection mode ends abnormally, the front differential and rear differential may be different from the specifications for the vehicle.

- When the rear differential inspection mode is interrupted, the following reasons are possible.

Message | Main reasons for abnormal termination | Action to take
[Inspection is stopped.] [Inspection is stopped. Restart this inspection mode from the beginning.] | TCM has detected a failure. | Perform the diagnosis for TCM. TRANSMISSION (DIAGNOSTICS)>Basic Diagnostic Procedure
VDC has a failure. | Perform the diagnosis for VDC. BRAKE CONTROL (DIAGNOSTICS)>Basic Diagnostic Procedure
Brake is applied after start during automatic running. | —
Too delayed operation to the instructions displayed on the Subaru Select Monitor. | —
[TCM incompatible. Rear differential inspection mode is stopped.] | The model does not support the rear differential inspection mode. | Check the specifications.
[The TCM has detected a fault. Inspect following the manual.] | TCM has detected a failure. | Perform the diagnosis for TCM. TRANSMISSION (DIAGNOSTICS)>Basic Diagnostic Procedure

DIFFERENTIALS > Symptoms and causes
INSPECTION

If noise occurs, identify the cause before work.

Symptoms | Problem parts etc. | Possible cause
Noise when shifting from P range or N range or starting | Hypoid gear set | Excessive hypoid gear backlash
Drive pinion or companion flange | Wear or damage at splines of drive pinion or companion flange
Self-locking nut securing the companion flange | Loose self-locking nut
Front bearing or rear bearing | Insufficient preload for front bearing or rear bearing
Washer | Excessive backlash between the differential bevel gear and differential bevel pinion
Differential bevel gear | Wear or damage of the splines
Pinion gear or pinion shaft | Wear or damage at connection of pinion gear and pinion shaft
Rear differential front member or rear differential mount bushing | Excessive hardening or damage of rear differential front member and rear differential mount bushing
Noise when turning | Differential bevel gear, differential bevel pinion | Damaged gear
Pinion shaft | Excessive wear or damage of pinion shaft
Washer | Excessive wear or damage of thrust washer
Noise when driving (under constant load) | Each bearing | Wear, damage or seizure of each bearing
Each gear | Damage of each gear