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Home >> Subaru >> 2017 >> Outback 2.5i >> Repair and Diagnosis (Single Page) >> Transmission >> Automatic Trans >> Continuously Variable Transaxle (CVT) (H4DO) >> Front Differential Assembly >> Assembly >> Differential Case Assembly

Differential Case Assembly

  1. Install the washer and differential bevel gear into the differential case (RH).
    Fig 1: Washer, Differential Bevel Gear And Differential Case (RH)
    G09478242Courtesy of SUBARU OF AMERICA, INC.
  2. Install the differential bevel pinions into differential case (RH) and install the pinion shaft.
    Fig 2: Pinion Shaft, Differential Bevel Gear And Differential Bevel Pinion
    G11573099Courtesy of SUBARU OF AMERICA, INC.
  3. Install the straight pin.
    Fig 3: Locating Straight Pin
    G09478238Courtesy of SUBARU OF AMERICA, INC.
  4. Install the washer and differential bevel gear to the differential case (LH).
    Fig 4: Washer, Differential Bevel Gear And Differential Case (LH)
    G09478245Courtesy of SUBARU OF AMERICA, INC.
  5. Install the differential case (RH) to the hypoid driven gear.
    Fig 5: Differential Case (RH) And Hypoid Driven Gear
    G09478246Courtesy of SUBARU OF AMERICA, INC.
  6. Install the differential case (LH) to the differential case (RH).
  7. Using the ST, install the hypoid driven gear by tightening the installation bolt.

    ST 18270KA020 SOCKET (E20)

    Tightening torque: 

    64 N.m (6.5 kgf-m, 47.2 ft-lb) 

    Fig 6: Installing Hypoid Driven Gear Using Socket - E20 (18270KA020)
    G09478247Courtesy of SUBARU OF AMERICA, INC.
  8. Measure the backlash, and select the washer.
    1. Install the SUBARU genuine axle shaft to differential case.

      Part No. 38415AA070 Axle shaft

    2. Using ST1 and ST2, insert the ST2 through the window of differential case. Measure the backlash of the gear.
      NOTE:
      • Measure the backlash by applying a differential bevel pinion tooth between two differential bevel gear teeth.
      • When measuring, fix the differential bevel pinion in place with a screwdriver covered with cloth, or a similar tool.

      ST1 498247001 MAGNET BASE

      ST2 498247100 DIAL GAUGE

      Specification: 

      0.13 - 0.18 mm (0.0051 - 0.0071 in) 

      Fig 7: Measuring Backlash Of Gear Using Magnet Base (498247001) And Dial Gauge (498247100)
      G09478248Courtesy of SUBARU OF AMERICA, INC.
    3. If the backlash is not within specification, select a washer from the table below and replace.
    Washer
    Part No. Thickness mm (in)
    803038021 0.95 (0.037)
    803038022 1.00 (0.039)
    803038023 1.05 (0.041)
  9. Using the ST, install the left and right taper roller bearings.

    ST1 499277100 BUSHING 1-2 INSTALLER

    ST2 398497701 SEAT

Fig 8: Installing Left And Right Taper Roller Bearings Using Bushing 1-2 Installer (499277100) And Seat (398497701)
G09478249Courtesy of SUBARU OF AMERICA, INC.
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