Drive Pinion Shaft Assembly: Adjustment

Remove the liquid gasket from the mating surface completely.
Install the oil pump housing assembly to the converter case, and secure them by tightening the 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)

Fig 1: Identifying Oil Pump Housing Assembly
Courtesy of SUBARU OF AMERICA, INC.
Rotate the drive pinion a few times using ST1 and ST2.
ST1 498937110 HOLDER

ST2 499787700 WRENCH

Fig 2: Rotating Drive Pinion Using Special Tools
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 back and forward several times. Remove the oil pump housing, and check the teeth contact pattern.
If the teeth contact is inappropriate, adjust the backlash and thickness of the drive pinion 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 3: Identifying Tooth Contact Surface Toe And Heel Side
  Courtesy of SUBARU OF AMERICA, INC.
- Face contact
  Check item: Backlash is too large.
  
  Contact pattern
  
  Fig 4: Identifying Face Contact Pattern
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Increase thickness of drive pinion shim according to the procedures for moving the drive pinion shaft close to hypoid driven gear.
  
  Fig 5: Adjusting Drive Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
- Flank contact
  Check item: Backlash is too small.
  
  Contact pattern
  
  Fig 6: Identifying Flank Contact Pattern
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion shaft away from the hypoid driven gear.
  
  Fig 7: Adjusting Drive Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
- Toe contact (inside contact)
  Check item: Teeth contact area is too small.
  
  Contact pattern
  
  Fig 8: Identifying Toe Contact Pattern (Inside Contact)
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion shaft away from the hypoid driven gear side.
  
  Fig 9: Adjusting Drive Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
- Heel contact (outside end contact)
  Check item: Teeth contact area is too small.
  
  Contact pattern
  
  Fig 10: Identifying Heel Contact Pattern (Outside End Contact)
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Increase thickness of drive pinion shim according to the procedures for moving the drive pinion shaft close to hypoid driven gear.
  
  Fig 11: Adjusting Drive Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
If tooth contact is correct, mark the differential side retainer position and loosen. After fitting the O-ring and oil seal, screw in the differential side retainer to the marked position. Install the lock plate, and tighten the bolts to the specified torque.
NOTE:
- Use new O-rings and oil seals.
- Apply gear oil to the O-ring and oil seal lip.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 12: Identifying Lock Plate
Courtesy of SUBARU OF AMERICA, INC.