Differential Case Assembly

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

Install the differential bevel gear and differential bevel pinion together with adjusting washer, and insert the pinion shaft.
NOTE: Face the chamfered side of adjusting washer toward bevel gear.

Fig 1: Identifying Differential Case Assembly Components
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Measure the backlash between the differential bevel gear and differential bevel pinion. Adjust the backlash if not within specified limit. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Front Differential Assembly>INSPECTION>DIFFERENTIAL BEVEL PINION GEAR BACKLASH .
NOTE: Be sure the pinion gear teeth contacts adjacent gear teeth during measurement.
Standard backlash
0.13-0.18 mm (0.0051-0.0071 in)
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE

Fig 2: Measuring Backlash Between Differential Bevel Gear And Differential Bevel Pinion
Courtesy of SUBARU OF AMERICA, INC.
Align the pinion shaft pin hole with the differential case pin hole, and drive the straight pin into the holes from the hypoid driven gear side using the ST.
NOTE:
- Use a new straight pin.
- After driving the straight pin, crimp the area around the hole, and make sure that the straight pin will not come out.
ST 899904100 STRAIGHT PIN REMOVER
Fig 3: Installing Straight Pin Into Holes From Hypoid Driven Gear Side Using ST
Courtesy of SUBARU OF AMERICA, INC.
Install the taper roller bearing.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Be careful when handling because the taper roller bearing and the outer race are used as a set.
ST1 499277100 BUSHING 1-2 INSTALLER
ST2 398497701 SEAT

Fig 4: Installing Taper Roller Bearing
Courtesy of SUBARU OF AMERICA, INC.
Install the hypoid driven gear using twelve bolts.
Tightening torque:

T: 62 N.m (6.3 kgf-m, 45.7 ft-lb)

Fig 5: Identifying Hypoid Driven Gear And Differential Case Bolts With Torque Specification

Courtesy of SUBARU OF AMERICA, INC.