Front Differential: Reassembly

Install pinions, bevel gears, and washers. Insert pinion shaft. Install washers with chamfered side toward gears.

Measure backlash between bevel gears and pinions. Ensure pinion gear tooth contacts adjacent gear teeth during measurement. If backlash is not .005-.007" (.13-.18 mm), select and install appropriate washer. See BEVEL GEAR WASHER SELECTION table.

BEVEL GEAR WASHER SELECTION

Part No.	Thickness In. (mm)
803038021	.0364-.0374 (.925-.95)
803038022	.0384-.0394 (.975-1.00)
803038023	.0404-.0413 (1.025-1.05)

Align pinion shaft hole with differential case hole. Drive and stake pin into position. Press roller bearings into differential case. Install hypoid driven gear. Tighten bolts to 42-49 ft. lbs. (57-67 N.m). Install drive shafts and snap rings. Measure clearance between shafts and case. See Fig 1. If clearance is not 0-.008" (0-.20 mm), select and install appropriate thichness snap ring. Refer to the SNAP RING SELECTION table.

Fig 1: Measuring Drive Shaft Clearance

Courtesy of SUBARU OF AMERICA, INC.

SNAP RING SELECTION

Part No.	Thickness In. (mm)
805028011	.0413 (1.05)
805028012	.0472 (1.20)