Front Differential: Installation

Install the differential assembly to the case, paying special attention not to damage the inside of the case (particularly, the differential side retainer contact surface).

Fig 1: Identifying Differential Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the new circlip to the axle shaft, insert the shaft into the differential assembly, and tap it into position with a plastic hammer. (Except TURBO model)
NOTE: If no play is felt, check whether the shaft is fully inserted. If shaft insertion is correct, replace the axle shaft.

Thrust play: 0.3 - 0.5 mm (0.012 - 0.020 in)
Wrap vinyl tape around the splined portion of the axle shaft. (Except TURBO model)
Install the O-rings from left and right side retainer.
Using ST, install the side retainers. < Ref. to REMOVAL . >
ST 499787000 WRENCH ASSY
Adjust the front differential backlash. < Ref. to ADJUSTMENT . >
Install the lock plate.
Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)

Fig 2: Identifying Lock Plate
Courtesy of SUBARU OF AMERICA, INC.
Install a new seal pipe to the torque converter clutch case.

Fig 3: Identifying Seal Pipe
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Install the torque converter clutch case to transmission case. < Ref. to INSTALLATION . >
Insert the inhibitor switch and transmission connector into stay.

Fig 4: Identifying Inhibitor Switch Harness And Transmission Harness
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Install the oil cooler pipes. < Ref. to INSTALLATION . >
Install the oil charger pipe with O-ring < Ref. to INSTALLATION . >
Insert the input shaft while turning it lightly by hand and verify the protrusion amount.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17 in)

Fig 5: Identifying Torque Converter Input Shaft Dimension
Courtesy of SUBARU OF AMERICA, INC.
Install the torque converter clutch assembly. < Ref. to INSTALLATION . >
Install the transmission assembly to the vehicle. < Ref. to INSTALLATION . >