Drive Pinion Shaft Assembly: Adjustment

Remove the liquid gasket from the mating surface completely.
Install the converter case to oil pump cover, and secure them with tightening four bolts evenly.
NOTE: Use an old gasket or aluminum washer to prevent damaging the mating surface of the housing.

Tightening torque: 41 N.m (4.2 kgf-m, 30.2 ft-lb)
Rotate the drive pinion a few times using ST1 and ST2.
ST1 18667AA010 HOLDER

ST2 499787700 WRENCH

Fig 1: Installing Converter Case To Oil Pump Cover
Courtesy of SUBARU OF AMERICA, INC.
Adjust the drive pinion and hypoid driven gear backlash. Refer to ADJUSTMENT , Front Differential Assembly.
Apply lead-free red dye evenly on the surface of three to four teeth of the hypoid driven gear. Rotate the drive pinion in the leftward and rightward for several times. Remove the oil pump cover, and check the tooth contact pattern.
If the teeth contact is inappropriate, adjust the backlash or thickness of the shim. Refer to ADJUSTMENT , Front Differential Assembly.
- 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 2: Identifying Tooth Contact Pattern - Correct Tooth Contact
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- Face contact
  Check item: Backlash is too large.
  
  Contact pattern
  
  Fig 3: Identifying Tooth Contact Pattern - Face Contact
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Increase the thickness of pinion height adjusting washer according to the procedures for moving the drive pinion closer to the driven gear.
  
  Fig 4: Identifying Thickness Of Pinion Height Adjusting Washer
  Courtesy of SUBARU OF AMERICA, INC.
- Flank contact
  Check item: Backlash is too small.
  
  Contact pattern
  
  Fig 5: Identifying Tooth Contact Pattern - Flank Contact
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Increase the thickness of pinion height adjusting washer according to the procedures for moving the drive pinion closer to the driven gear.
  
  Fig 6: Identifying Thickness Of Pinion Height Adjusting Washer
  Courtesy of SUBARU OF AMERICA, INC.
- Toe contact (inside contact)
  Check item: Contact area is too small.
  
  Contact pattern
  
  Fig 7: Identifying Tooth Contact Pattern - Toe Contact
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing the drive pinion away from driven gear.
  
  Fig 8: Identifying Thickness Of Pinion Height Adjusting Washer
  Courtesy of SUBARU OF AMERICA, INC.
- Heel contact (outside end contact)
  Check item: Contact area is too small.
  
  Contact pattern
  
  Fig 9: Identifying Tooth Contact Pattern - Contact Pattern
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing the drive pinion away from driven gear.
  
  Fig 10: Identifying Thickness Of Pinion Height Adjusting Washer
  Courtesy of SUBARU OF AMERICA, INC.
If tooth contact is correct, mark the retainer position and loosen it. After fitting a new O-ring and oil seal, screw in the retainer to the marked position. Tighten the lock plate with specified torque.
Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 11: Identifying Lock Plate
Courtesy of SUBARU OF AMERICA, INC.