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Front Differential Assembly: Adjustment

  1. Using the ST, screw-in the differential side retainer until light contact is felt.

    ST 499787000 WRENCH ASSY

    NOTE:
    • Screw-in the RH side slightly deeper than the LH side.
    • WRENCH ASSEMBLY (18630AA010) can also be used.
    Fig 1: Identifying Wrench Assembly
    G05002728Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the oil pump housing.
  3. Remove the liquid gasket from the mating surface completely.
  4. Install the oil pump housing assembly to the converter 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, 30.4 ft-lb) 

    Fig 2: Identifying Oil Pump Housing Assembly
    G05002696Courtesy of SUBARU OF AMERICA, INC.
  5. Rotate the drive pinion a few times using ST1 and ST2.

    ST1 498937110 HOLDER

    ST2 499787700 WRENCH

    Fig 3: Rotating Drive Pinion
    G05002697Courtesy of SUBARU OF AMERICA, INC.
  6. Tighten the differential side retainer LH until contact is felt while rotating the shaft. Then loosen the differential side retainer RH. Keep tightening the differential side retainer LH, and loosening the retainer RH until the pinion shaft no longer turns. This is the "zero" state.
    Fig 4: Identifying Differential Side Retainer
    G04994293Courtesy of SUBARU OF AMERICA, INC.
  7. After the "zero" state is established, back off the differential side retainer LH 3 notches and secure it with the lock plate. Then back off the differential side retainer RH and retighten until it stops. Rotate the drive pinion 2 or 3 times. Tighten the differential side retainer RH 1-3/4 notches further. This sets the preload. Finally, secure the differential side retainer with the lock plate.
    Fig 5: Identifying Lock Plate Location
    G04994294Courtesy of SUBARU OF AMERICA, INC.
    NOTE: Turning the differential side retainer by one notch changes the backlash about 0.05 mm (0.0020 in).
    Fig 6: Identifying Retainer Backlash Dimension
    G05002733Courtesy of SUBARU OF AMERICA, INC.
  8. Turn the drive pinion a few times with ST1 and check to see if the backlash is within the specified value, using ST2, ST3, ST4 and ST5.

    ST1 499787700 WRENCH

    ST2 498247001 MAGNET BASE

    ST3 498247100 DIAL GAUGE

    ST4 499787500 ADAPTER

    ST5 498255400 PLATE

    Backlash: 

    0.13 - 0.18 mm (0.0051 - 0.0071 in) 

    Fig 7: Identifying ST1, ST2,ST3,ST4 And ST5
    G05002734Courtesy of SUBARU OF AMERICA, INC.
  9. Adjust the teeth contact of the front differential and drive shaft. <Ref. to ADJUSTMENT  DRIVE PINION SHAFT ASSEMBLY. >
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