Drive Pinion Shaft Assembly: Inspection

• Make sure that all component parts are free of scratches, holes and other faults.
• Check the tooth contact. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Drive Pinion Shaft Assembly>ADJUSTMENT .
• Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.
• Check the bearing preload of drive pinion shaft.
  CAUTION: Before measuring, apply differential gear oil to roller of bearing and rotate the bearing several times.

  Starting torque: 

  16.3-42.7 N (1.7-4.4 kgf, 4.4-9.6 lbf)

Fig 1: Checking Drive Pinion Shaft Bearing Preload

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ADJUSTMENT 

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 2: Identifying Drive Pinion Retainer And Converter Case Bolts

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3. Rotate the drive pinion several times using ST1 and ST2.

   ST1 18667AA010 HOLDER 

   ST2 499787700 WRENCH 

   Fig 3: Rotating Drive Pinion Using Special Tools

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4. Adjust the drive pinion and hypoid driven gear backlash. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>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, adjust the backlash or thickness of the shim. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Front Differential Assembly>ADJUSTMENT .

   NOTE: After correction, wipe off the lead-free red dye.
   • 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 4: Identifying Hypoid Driven Gear Tooth Toe And Heel Sides

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   • Face contact

     Check item: Backlash is too large. 

     Contact pattern

     Fig 5: Identifying Hypoid Driven Gear Tooth Face Contact Pattern (Large Backlash)

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     Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.

     Fig 6: Increasing Pinion Height Adjusting Washer Thickness

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   • Flank contact

     Check item: Backlash is too small. 

     Contact pattern

     Fig 7: Identifying Hypoid Driven Gear Tooth Face Contact Pattern (Small Backlash)

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     Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.

     Fig 8: Reducing Pinion Height Adjusting Washer Thickness

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   • Toe contact (inside contact)

     Check item: Teeth contact area is too small. 

     Contact pattern

     Fig 9: Identifying Hypoid Driven Gear Tooth Face Contact Pattern (Small Teeth Contact Area)

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     Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear side.

     Fig 10: Reducing Pinion Height Adjusting Washer Thickness

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   • Heel contact (outside end contact)

     Check item: Teeth contact area is too small. 

     Contact pattern

   Fig 11: Identifying Hypoid Driven Gear Tooth Face Contact Pattern (Small Teeth Contact Area)

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

   Fig 12: Increasing Pinion Height Adjusting Washer Thickness

   Courtesy of SUBARU OF AMERICA, INC.
7. If tooth contact is correct, mark the differential side retainer position and loosen. After fitting a new O-ring and oil seal, screw in the differential side retainer to the marked position.
8. Tighten the lock plate with specified torque.

Tightening torque: 

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

Fig 13: Identifying Drive Pinion Shaft Assembly Lock Plate

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