Subaru Legacy IV (2008 year). Manual - part 822

 

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Subaru Legacy IV (2008 year). Manual - part 822

 

 

6MT-101

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

B: INSTALLATION

1) Install the differential assembly to the clutch
housing.
2) Apply oil to the screw threads of the side retain-
er.
3) Remove the O-rings on both sides of the side re-
tainer.
4) Install the differential side retainers to both
sides, using the ST.
ST1

18630AA010

WRENCH COMPL 
RETAINER (RH SIDE)

ST2

18630AA000

WRENCH ASSEMBLY 
(LH SIDE)

NOTE:
Be careful not to damage the oil seal.

5) Inspect and adjust the hypoid gear backlash.
<Ref. to 6MT-107, HYPOID GEAR BACKLASH,
INSPECTION, Front Differential Assembly.>
6) Inspect and adjust the tooth contact. <Ref. to
6MT-98, ADJUSTMENT, Drive Pinion Shaft As-
sembly.>

7) Mark the mating positions of the left and right
side retainers and the clutch housing.

8) Remove the differential side retainers from both
sides.

NOTE:
When removing the side retainer, record how many
times it was turned to remove.
9) Install new O-rings to the side retainers on both
sides.
10) Attach the differential side retainers to both
sides.

NOTE:
When attaching, turn the side retainer the same
number of turns it took to remove, and align the
marks.
11) Install the lock plate.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

NOTE:
Be careful not to confuse the left and right side lock
plates.

12) Remove any remaining liquid gasket from the
clutch housing and adapter plate.

(A) LH side

(B) RH side

(A)

(B)

MT-00657

ST1

ST2

(A) LH

(B) RH

MT-00658

MT-00659

(A)

(B)

6MT-102

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

13) Apply liquid gasket to the clutch housing.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or 
equivalent

14) Install the drive pinion shaft assembly. <Ref. to
6MT-94, INSTALLATION, Drive Pinion Shaft As-
sembly.>
15) Install the individual gear assemblies all at
once. <Ref. to 6MT-65, INSTALLATION, Main
Shaft Assembly.>
16) Install the transmission case. <Ref. to 6MT-60,
INSTALLATION, Transmission Case.>
17) Install the center differential. <Ref. to 6MT-57,
INSTALLATION, Center Differential.>
18) Install the transfer driven gear. <Ref. to 6MT-
55, INSTALLATION, Transfer Driven Gear.>
19) Install the extension case. <Ref. to 6MT-43, IN-
STALLATION, Extension Case.>
20) Install the neutral position switch, back-up light
switch and harness. <Ref. to 6MT-41, INSTALLA-
TION, Neutral Position Switch.> <Ref. to 6MT-39,
INSTALLATION, Back-up Light Switch.>
21) Install the manual transmission assembly to the
vehicle. <Ref. to 6MT-34, INSTALLATION, Manual
Transmission Assembly.>

C: DISASSEMBLY

1. DIFFERENTIAL CASE

1) Fix the differential assembly on a vise, and re-
move the hypoid driven gear.
ST

18270KA020

SOCKET (E20)

2) Using the ST, remove the roller bearing.
ST

399527700

PULLER SET

3) Using the ST, remove the roller bearing.
ST

498077000

REMOVER

4) Remove the differential case LH.

MT-00532

MT-00660

MT-00663

ST

MT-00665

ST

MT-01532

6MT-103

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

5) Remove the differential bevel gear and washer.

6) Using a magnet tool, etc., remove 3 straight
pins.

7) Remove 3 pinion shafts.

8) Remove differential bevel pinion and pinion shaft
joint.

9) Remove the differential bevel gear and washer.

2. SIDE RETAINER

1) Remove the O-ring.

2) Remove the oil seal.

(A) Differential bevel gear

(B) Washer

(A) Straight pin

MT-01533

(B)

(A)

MT-01534

(A)

(A)

(A)

MT-01535

(A) Differential bevel pinion

(B) Pinion shaft joint

MT-01536

(A)

(B)

MT-00666

AT-00220

6MT-104

Front Differential Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

3) Remove the claw of ST1, and attach the claw of
ST2.
ST1

398527700

PULLER ASSY

ST2

18760AA000

CLAW

4) Remove the bearing outer race from the side re-
tainer, using the ST.
ST1

398527700

PULLER ASSY

ST2

18760AA000

CLAW

D: ASSEMBLY

1. DIFFERENTIAL CASE

1) Install differential bevel gear and washer to the
differential case RH.

NOTE:
Face the chamfered side of washer toward gear.

2) Install differential bevel pinion and pinion shaft
joint.

3) Install 3 pinion shafts.

(A) CLAW

(A) Side retainer

MT-00668

(A)

ST2

ST1

MT-00669

(A)

ST2

ST1

(A) Differential bevel pinion

(B) Pinion shaft joint

MT-01537

MT-01536

(A)

(B)

MT-01535

 

 

 

 

 

 

 

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