Drive Pinion Shaft Assembly: Adjustment

Assemble the drive pinion shaft assembly to oil pump cover.
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
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 Correct Tooth Contact Pattern
  Courtesy of SUBARU OF AMERICA, INC.
- Face contact
  Check item: Backlash is too large.
  
  Contact pattern
  
  Fig 3: Identifying Tooth Face Contact Pattern (Backlash Large)
  Courtesy of SUBARU OF AMERICA, INC.
  
  Adjustment: Increase the thickness of the shim according to the procedures for moving the drive pinion closer to the driven gear.
  
  Fig 4: Moving Drive Pinion Closer To Driven Gear
  Courtesy of SUBARU OF AMERICA, INC.
- Flank contact
  Check item: Backlash is too small.
  
  Contact pattern
  
  Fig 5: Identifying Tooth Flank Contact Pattern (Backlash Too Small)
  Courtesy of SUBARU OF AMERICA, INC.
  
  Adjustment: Reduce the thickness of the shim according to the procedure for moving the drive pinion away from the driven gear.
  
  Fig 6: Moving Drive Pinion Away From Driven Gear
  Courtesy of SUBARU OF AMERICA, INC.
- Toe contact (inside contact)
  Check item: Teeth contact area is too small.
  
  Contact pattern
  
  Fig 7: Identifying Tooth Toe Contact Pattern (Teeth Contact Area Too Small)
  Courtesy of SUBARU OF AMERICA, INC.
  
  Adjustment: Reduce the thickness of the shim according to the procedure for moving the drive pinion away from the driven gear.
  
  Fig 8: Moving Drive Pinion Away From Driven Gear
  Courtesy of SUBARU OF AMERICA, INC.
- Heel contact (outside end contact)
  Check item: Teeth contact area is too small.
  
  Contact pattern
  
  Fig 9: Identifying Tooth Heel Contact Pattern (Teeth Contact Area Too Small)
  Courtesy of SUBARU OF AMERICA, INC.
  
  Adjustment: Increase the thickness of the shim according to the procedures for moving the drive pinion closer to the driven gear.
  
  Fig 10: Moving Drive Pinion Closer To Driven Gear
  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.