Differential Case Assembly

WARNING: This page is about a different car, the 2004 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: Installing Bevel Gear, Bevel Pinion & Pinion Shaft
Courtesy of SUBARU OF AMERICA, INC.
Measure the backlash between bevel gear and pinion. If it is not within specifications, install a suitable washer to adjust it. < Ref. to ADJUSTMENT . >
NOTE: Be sure the pinion gear tooth contacts adjacent gear teeth during measurement.

ST1 498247001 MAGNET BASE

ST2 498247100 DIAL GAUGE

Standard backlash:

0.13 - 0.18 mm (0.0051 - 0.0071 In)

Fig 2: Checking Backlash Between Bevel Gear & Pinion
Courtesy of SUBARU OF AMERICA, INC.
Align the pinion shaft and differential case at their holes, and drive the straight pin into holes from the hypoid driven gear side, using ST.
NOTE: Lock the straight pin after installing.

ST 899904100 REMOVER

Fig 3: Installing Straight Pin
Courtesy of SUBARU OF AMERICA, INC.
Install the roller bearing to differential case.
NOTE:
- Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
- Be careful because the roller bearing outer races are used as a set.
ST1 499277100 BUSH 1-2 INSTALLER

ST2 398497701 ADAPTER

Fig 4: Installing Roller Bearing To Differential Case
Courtesy of SUBARU OF AMERICA, INC.
Install the hypoid driven gear to differential case using twelve bolts.
Tightening torque:

T: 62 N.m (6.3 kgf-m, 45.6 ft-lb)

Fig 5: Installing Hypoid Driven Gear To Differential Case
Courtesy of SUBARU OF AMERICA, INC.

Set the drive axle shaft into differential case and hold it using outer spring. Measure the shaft to case clearance to check if it is within specifications using thickness gauge.

NOTE: Replace the snap ring with suitable one, if the measurement is not within specifications.

SNAP RING (OUTER) THICKNESS SPECIFICATION

Part No.	Thickness mm (in)
805028011	1.05 (0.0413)
805028012	1.20 (0.0472)

Clearance

0 - 0.2 mm (0 - 0.008 in)

Fig 6: Checking Pinion Shaft To Case Clearance

Courtesy of SUBARU OF AMERICA, INC.