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: Rotating Drive Pinion Using ST1 And ST2
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Adjust the drive pinion and hypoid driven gear backlash. Ref. to ADJUSTMENT , Front Differential Assembly.
Apply lead-free red dye evenly to the surfaces of three or four teeth on 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 shim thickness. Ref. 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 Correct Tooth Contact Pattern
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- Face contact
  Check item: Backlash is too large.
  
  Contact pattern
  
  Fig 3: Identifying Contact Pattern
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  Corrective action: Increase the thickness of pinion height adjusting washer according to the procedure for bringing the drive pinion close to the driven gear.
  
  Fig 4: Adjusting Drive Pinion Height
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- Flank contact
  Check item: Backlash is too small.
  
  Contact pattern
  
  Fig 5: Identifying Contact Pattern
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  Adjustment: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive the pinion away from driven gear.
  
  Fig 6: Adjusting Drive Pinion Height
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- Toe contact (inside contact)
  Check item: Contact area is too small.
  
  Contact pattern
  
  Fig 7: Identifying Contact Pattern
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  Adjustment: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from driven gear side.
  
  Fig 8: Adjusting Drive Pinion Height
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- Heel contact (outside end contact)
  Check item: Contact area is too small.
  
  Contact pattern
  
  Fig 9: Identifying Contact Pattern
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  Corrective action: Increase thickness of pinion height adjusting washer in order to bring drive pinion close to driven gear.
  
  Fig 10: Adjusting Drive Pinion Height
  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
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