Drive Pinion Shaft Assembly: Adjustment

WARNING: This page is about a different variant/trim than selected.

Remove the liquid gasket from the mating surface completely.
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 1: Identifying Mating Surface Of Housing
Courtesy of SUBARU OF AMERICA, INC.
Rotate the drive pinion a few times using ST1 and ST2.
ST1 498937110 HOLDER

ST2 499787700 WRENCH

Fig 2: Identifying Drive Pinion Several Times With ST1 And ST2
Courtesy of SUBARU OF AMERICA, INC.
Adjust the drive pinion and driven gear backlash. < Ref. to ADJUSTMENT , Front Differential Assembly. >
Apply red lead evenly to the surfaces of three or four teeth on the driven gear. Rotate the drive pinion back and forward several times. Remove the oil pump housing, and check the teeth contact pattern. If the teeth contact is inappropriate, adjust the backlash or thickness of the shim. < Ref. to ADJUSTMENT , Front Differential Assembly. >
- Correct tooth contact
  Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.)
  
  Fig 3: Identifying Correct Tooth Contact
  Courtesy of SUBARU OF AMERICA, INC.
- Face contact
  Checking item: Backlash is too large.
  
  Contact pattern
  
  Fig 4: Identifying Contact Tooth Pattern
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Increase thickness of pinion height adjusting washer according to the procedures for moving the drive pinion closer to the driven gear.
  
  Fig 5: Adjusting Drive Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
- Flank contact
  Checking item: Backlash is too small.
  
  Contact pattern
  
  Fig 6: Identifying Flank Tooth Contact Pattern
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Reduce thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion away from the driven gear.
  
  Fig 7: Adjusting Drive Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
- Heel contact (outside end contact)
  Check item: Teeth contact area is too small.
  
  Contact pattern
  
  Fig 8: Identifying Contact Pattern
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Reduce thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion away from the driven gear side.
  
  Fig 9: Adjusting Drive Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
- Toe contact (inside end contact)
  Check item: Teeth contact area is too small.
  
  Contact pattern
  
  Fig 10: Identifying Contact Pattern
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Increase thickness of pinion height adjusting washer according to the procedures for moving the drive pinion closer to the driven gear.
  
  Fig 11: Adjusting Drive Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
If tooth contact is correct, mark the retainer position and loosen it. After fitting a new O-ring and oil seal, screw in the retainer to the marked position. Tighten the lock plate with specified torque.
Tightening torque:

25 N.m (2.5 kgf-m, 18 ft-lb)

Fig 12: Identifying Tooth Contact
Courtesy of SUBARU OF AMERICA, INC.