Subaru Legacy IV (2008 year). Manual - part 873

DI-41

Rear Differential (T-type)

DIFFERENTIALS

Initial torque:

0.67 — 1.47 N·m 
(0.07 — 0.15 kgf-m, 0.49 — 1.08 ft-lb)

12) Assembling differential case
Install the side gears and pinion mate gears, with
their thrust washers and pinion mate shaft, into the
differential case. (Model without LSD)

NOTE:
• Apply gear oil on both sides of the washer and on
the side gear shaft before installing.
• Insert the pinion mate shaft into the differential
case by aligning the lock pin holes.

(1) Measure the side gear backlash.

Side gear backlash:

0.10 — 0.20 mm (0.004 — 0.008 in)

(2) Adjust the backlash as specified by select-
ing the side gear thrust washers.

(3) Check the condition of rotation after apply-
ing oil to the gear tooth surfaces and thrust
washer surfaces.
(4) After inserting the pinion shaft lock pin into
differential case, stake the both sides of the
hole to prevent pin from falling off.

13) Install the driven gear to the differential case.

NOTE:
Before installing bolts, apply seal material to bolt
threads.

SEAL MATERIAL:

THREE BOND 1324 (Part No. 004403042) or 
equivalent

NOTE:
• Make sure there is no clearance between the dif-
ferential case and driven gear.
• Tighten diagonally.

Tightening torque:

103 N·m (10.5 kgf-m, 76.0 ft-lb)

DI-00481

DI-00239

Side gear thrust washer

Part No.

Thickness mm (in)

383445201

075 — 0.80 (0.0295 — 0.0315)

383445202

0.80 — 0.85 (0.0315 — 0.0335)

383445203

0.85 — 0.90 (0.0335 — 0.0354)

DI-00240

DI-00068

DI-42

Rear Differential (T-type)

DIFFERENTIALS

14) Press the side bearing into differential case us-
ing ST.
ST

398487700

DRIFT

15) Press-fit the side bearing race into side retainer
using ST.
ST

398417700

DRIFT

16) Adjusting side retainer shims

(1) The hypoid driven gear backlash and side
bearing preload can be adjusted by the side re-
tainer shim thickness.
(2) Install the differential case assembly into dif-
ferential carrier in the reverse order of disas-
sembly.

NOTE:
Be careful not to hit the teeth against the case.

(3) Install the side retainer shims and O-ring to
retainers RH and LH on which they were in-
stalled.

NOTE:
• Replace the O-ring with a new part.
• Replace broken or corroded side retainer shims
with a new part of the same thickness.

(4) When installing, align the arrow mark on the
differential carrier with the mark on the side re-
tainer.

NOTE:
Be careful that the bearing roller does not damage
the side bearing race.

(5) Tighten the side retainer bolts.

Tightening torque:

10.5 N·m (1.1 kgf-m, 7.7 ft-lb)

ST

DI-00095

DI-00324

ST

DI-00065

Side retainer shim

Part No.

Thickness mm (in)

383475201

0.20 (0.0079)

383475202

0.25 (0.0098)

383475203

0.30 (0.0118)

383475204

0.40 (0.0157)

383475205

0.50 (0.0197)

(A) Arrow mark (Side retainer side)

(B) Arrow mark (Differential carrier side)

DI-00543

(B)

(A)

DI-00487

DI-43

Rear Differential (T-type)

DIFFERENTIALS

(6) Measure the backlash between the hypoid
driven gear and drive pinion. Set the magnet
base on differential carrier. Align the contact
point of dial gauge with tooth face of hypoid
driven gear, and move hypoid driven gear while
holding drive pinion still. Read the value indicat-
ed on dial gauge. If the backlash is outside the
standard range, adjust the side retainer shim by
the following method.
• When backlash is less than 0.1 mm (0.004 in):
Reduce the hypoid driven gear rear face shim
thickness and increase the hypoid driven gear
tooth surface side shim thickness.
• When backlash exceeds 0.2 mm (0.008 in):
Increase the thickness of shim on the back side
of the hypoid driven gear and reduce the thick-
ness of shims on the teeth side of the hypoid
driven gear.

Backlash:

0.10 — 0.20 mm (0.004 — 0.008 in)

(7) At the same time, measure the total preload
of the drive pinion. Compared with the resis-
tance when differential case is not installed, if
the total preload is not within specification, ad-
just the thickness of side retainer shims, in-
creasing/reducing both shims by an even
amount at a time.

Total preload:

20.7 — 54.4 N (2.1 — 5.5 kgf, 4.7 — 12.2 lb)

17) Recheck the hypoid driven gear to pinion back-
lash.

Backlash:

0.10 — 0.20 mm (0.004 — 0.008 in)

18) Check the hypoid driven gear runout on its
back surface, and make sure that the pinion and
hypoid driven gear rotates smoothly.
If the hypoid driven gear runout on its back surface
exceeds the specification, check for any foreign ob-
jects between the hypoid driven gear and differen-
tial case, and for any deformation of the case or
gear.

Hypoid driven gear runout on its back surface:

0.05 mm (0.002 in)

19) Checking and adjusting the tooth contact of hy-
poid driven gear

(1) Apply lead-free red dye evenly on the both
sides of three to four teeth of the hypoid driven
gear. Check the contact pattern after rotating
the hypoid driven gear several revolutions back
and forth until a definite contact pattern appears
on the hypoid driven gear.
(2) When the contact pattern is not correct, re-
adjust.

NOTE:
Be sure to wipe off the lead-free red lead after the
adjustment is completed.

• Correct tooth contact
Check item: Tooth contact pattern is slightly
shifted towards the toe side under no-load
rotation. (When driving, it moves towards
the heel side.)

DI-00099

DI-00099

(A) Toe side

(B) Heel side

DI-00101

(A)

(B)

MT-01401

DI-44

Rear Differential (T-type)

DIFFERENTIALS

• Face contact
Check item: Backlash is too large.
Contact pattern

Corrective action: Increase thickness of drive
pinion height adjusting washer in order to bring
drive pinion close to hypoid driven gear.

• Flank contact
Check item: Backlash is too small.
Contact pattern

Corrective action: Reduce the thickness of pin-
ion height adjusting washer according to the
procedure for bringing drive pinion away from
hypoid driven gear.

• Toe contact (inside contact)
Check item: Contact area is too small.
Contact pattern

Corrective action: Reduce the thickness of pin-
ion height adjusting washer according to the
procedure for bringing drive pinion away from
hypoid driven gear.

• Heel contact (outside end contact)
Check item: Contact area is too small.
Contact pattern

Corrective action: Increase thickness of drive
pinion height adjusting washer in order to bring
drive pinion close to hypoid driven gear.

AT-00208

AT-00212

AT-00209

AT-00213

AT-00210

AT-00213

AT-00211

AT-00212