Differential Case Assembly

1. Install the bevel gear and bevel pinion together with washers, and insert the pinion shaft.
   NOTE: Face the chamfered side of washer toward gear.
   Fig 1: Inserting Pinion Shaft

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2. Measure the backlash between bevel gear and pinion. If it is not within specifications, install a suitable washer to adjust. < Ref. to , ADJUSTMENT , Front Differential Assembly. >
   NOTE: Be sure the pinion gear teeth contacts adjacent gear teeth during measurement.

   ST1 498247001 MAGNET BASE

   ST2 498247100 DIAL GAUGE

   Standard backlash 

   0.13 - 0.18 mm (0.0051 - 0.0071 in) 

   Fig 2: Measuring Backlash Between Bevel Gear And Pinion

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3. Align the pinion shaft and differential case at their holes, and drive the straight pin into holes from the hypoid driven gear side, using ST.
   NOTE: Lock the straight pin after installing.

   ST 899904100 REMOVER

   Fig 3: Aligning Pinion Shaft And Differential Case At Their Holes

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4. Install the roller bearing to differential case.
   NOTE:

   • Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
   • Be careful because the roller bearing outer races are used as a set.

   ST1 499277100 BUSHING 1-2 INSTALLER

   ST2 398497701 ADAPTER

   Fig 4: Installing Roller Bearing To Differential Case

   Courtesy of SUBARU OF AMERICA, INC.
5. Install the hypoid driven gear to differential case using twelve bolts.

Tightening torque: 

T: 62 N.m (6.3 kgf-m, 45.6 ft-lb) 

Fig 5: Installing Hypoid Driven Gear To Differential Case

Courtesy of SUBARU OF AMERICA, INC.