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Drive Pinion Shaft Assembly: Adjustment

WARNING: This page is about a different variant/trim than selected.
  1. Remove the liquid gasket from the mating surface completely.
  2. Using the ST, install the drive pinion retainer to converter case.

    ST 18270KA020 SOCKET (E20) 

    NOTE: Do not confuse the three different-length bolts when installing.

    Tightening torque: 

    43 N.m (4.4 kgf-m, 31.7 ft-lb)

    Fig 1: Identifying Drive Pinion Retainer To Converter Case Different-Length Bolts
    G08318086Courtesy of SUBARU OF AMERICA, INC.
  3. Rotate the drive pinion several times using ST1 and ST2.

    ST1 498937110 HOLDER 

    ST2 499787700 WRENCH 

    Fig 2: Rotating Drive Pinion Using ST1 And ST2
    G08318121Courtesy of SUBARU OF AMERICA, INC.
  4. Adjust the drive pinion and hypoid driven gear backlash. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>Front Differential Assembly>ADJUSTMENT .
  5. Using the ST, remove the drive pinion retainer from converter case.

    ST 18270KA020 SOCKET (E20) 

  6. Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Then install the drive pinion retainer and rotate the drive pinion in both directions several times.

    Remove the drive pinion retainer and check the tooth contact pattern. If the teeth contact is inappropriate, readjust the backlash and shim thickness (Select 1 - 3 shims.). Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>Front Differential Assembly>ADJUSTMENT .

    NOTE: After correction, wipe off the lead-free red dye.
    Drive pinion shim
    Part No. Thickness mm (in)
    31451AA320 0.150 (0.0059)
    31451AA330 0.175 (0.0069)
    31451AA340 0.200 (0.0079)
    31451AA350 0.225 (0.0089)
    31451AA360 0.250 (0.0098)
    31451AA370 0.275 (0.0108)
    • 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 Hypoid Driven Gear Tooth Contact Pattern (Correct Tooth Contact)
      G11265831Courtesy of SUBARU OF AMERICA, INC.
    • Face contact

      Check item: Backlash is too large. 

      Contact pattern

      Fig 4: Identifying Hypoid Driven Gear Tooth Contact Pattern (Face Contact)
      G06654698Courtesy of SUBARU OF AMERICA, INC.

      Corrective action: Increase thickness of drive pinion shim according to the procedures for moving the drive pinion close to hypoid driven gear.

      Fig 5: Moving Drive Pinion Closer To Hypoid Driven Gear
      G10317723Courtesy of SUBARU OF AMERICA, INC.
    • Flank contact

      Check item: Backlash is too small. 

      Contact pattern

      Fig 6: Identifying Hypoid Driven Gear Tooth Contact Pattern (Flank Contact)
      G10321305Courtesy of SUBARU OF AMERICA, INC.

      Corrective action: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion away from the hypoid driven gear.

      Fig 7: Moving Drive Pinion Away From Hypoid Driven Gear
      G10317721Courtesy of SUBARU OF AMERICA, INC.
    • Toe contact (inside contact)

      Check item: Teeth contact area is too small. 

      Contact pattern

      Fig 8: Identifying Hypoid Driven Gear Tooth Contact Pattern - Toe Contact (Inside Contact)
      G10406667Courtesy of SUBARU OF AMERICA, INC.

      Corrective action: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion away from the hypoid driven gear side.

      Fig 9: Moving Drive Pinion Away From Hypoid Driven Gear Side
      G10317719Courtesy of SUBARU OF AMERICA, INC.
    • Heel contact (outside end contact)

      Check item: Teeth contact area is too small. 

      Contact pattern

      Fig 10: Identifying Hypoid Driven Gear Tooth Contact Pattern - Heel Contact (Outside End Contact)
      G10317722Courtesy of SUBARU OF AMERICA, INC.

      Corrective action: Increase the thickness of the drive pinion shim according to the procedures for moving the drive pinion closer to the hypoid driven gear.

    Fig 11: Moving Drive Pinion Closer To Hypoid Driven Gear
    G10317717Courtesy of SUBARU OF AMERICA, INC.
  7. Using the ST, loosen the differential side retainer until the mounting groove of the O-ring appears, and then install the O-ring.
    NOTE:
    • When loosening the differential side retainer, record the number of the turns made.
    • Perform this for both left and right differential side retainers.
    • Use new O-rings.
    • Apply the differential gear oil to O-ring.

    ST 18658AA020 WRENCH COMPL RETAINER 

  8. Using the ST, tighten the retainer to the position before it is loosened.

    ST 18658AA020 WRENCH COMPL RETAINER 

  9. Replace the differential side retainer oil seal with a new part. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>Differential Side Retainer Oil Seal .
  10. Install the lock plate.

    Tightening torque: 

    25 N.m (2.5 kgf-m, 18.4 ft-lb)

    Fig 12: Installing Lock Plate
    G11265840Courtesy of SUBARU OF AMERICA, INC.
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