Subaru Legacy IV (2008 year). Manual - part 876

DI-53

Rear Differential (T-type)

DIFFERENTIALS

• 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.

25) If proper tooth contact is not obtained, readjust
the drive pinion height by changing the RH and LH
side retainer shims and the hypoid gear backlash.
26) Install oil seals to the side retainers on both
sides. <Ref. to DI-88, REPLACEMENT, Rear Dif-
ferential Side Oil Seal.>
27) When installing, align the arrow mark on the dif-
ferential carrier with the mark on the side retainer.

28) Apply liquid gasket to the bolts indicated by ar-
rows, and tighten the side retainer bolt.

Liquid gasket:

THREE BOND 1110B (Part No. K0879Y0020) 
or equivalent

Tightening torque:

10.5 N·m (1.1 kgf-m, 7.7 ft-lb)

29) Install the new gasket and rear cover, and tight-
en the bolts to specified torque.

Tightening torque:

44 N·m (4.5 kgf-m, 32.5 ft-lb)

30) Install the breather cap.
31) Install the oil drain plug and filler plug.

Tightening torque:

60 N·m (6.1 kgf-m, 44.3 ft-lb)

(A) Arrow mark (Side retainer side)

(B) Arrow mark (Differential carrier side)

AT-00211

AT-00212

DI-00543

(B)

(A)

DI-00461

DI-00560

DI-54

Rear Differential (T-type)

DIFFERENTIALS

E: INSPECTION

Wash all the disassembled parts clean, and exam-
ine them for wear, damage and other defects. Re-
pair or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
• If there is evidently an abnormal tooth contact,
find out the cause and adjust until the teeth contact
correctly. Replace the gear if there is an excessive
worn or an incapable adjustment.
• If crack, cutout or seizure is found, replace the
parts as a set. Slight damage of some teeth can be
corrected by oil stone or the like.
2) Side gear and pinion mate gear
• Replace if cracks, scoring or other defects are
evident on the tooth surface.
• Replace if thrust washer contact surface is worn
or seized. Slight damages of the surface can be
corrected by oil stones or equivalent.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, abnormal noise or other defect is
evident.
4) Thrust washer of the side gear and pinion mate gear
Replace if seized, flawed, abnormally worn or hav-
ing other defects.
5) Oil seal
Replace if deformed or damaged, and at every dis-
assembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are abnormally worn,
burned, or cracked.
8) Companion flange
Replace if the oil seal lip contact surface shows
cracking.

1. SIDE GEAR BACKLASH

Using a dial gauge, check the backlash of side
gear. (Model without LSD)

Side gear backlash:

0.1 — 0.2 mm (0.004 — 0.008 in)

If the side gear backlash is not within the specifica-
tion, select the side gear thrust washer and adjust
the side gear backlash as specified.

2. HYPOID DRIVEN GEAR BACKLASH

Using a dial gauge, check the backlash of hypoid
driven gear.

Hypoid driven gear backlash:

0.1 — 0.2 mm (0.004 — 0.008 in)

If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or re-
pair if necessary.

3. HYPOID DRIVEN GEAR RUNOUT ON ITS 
BACK SURFACE

Using a dial gauge, check the hypoid driven gear
back surface runout.

Hypoid driven gear back surface runout:

0.05 mm (0.002 in)

If the hypoid driven gear runout exceeds 0.05 mm
(0.002 in), replace the hypoid driven gear.

4. TOOTH CONTACT BETWEEN HYPOID 
DRIVEN GEAR AND DRIVE PINION

Inspect the tooth contact between the hypoid driv-
en gear and drive pinion. <Ref. to DI-37, ASSEM-
BLY, Rear Differential (T-type).>

DI-00315

DI-00099

DI-00101

DI-55

Rear Differential (T-type)

DIFFERENTIALS

5. TOTAL PRELOAD

Using a spring scale, check the total preload.

Total preload:

Except for GT spec. B 6MT model:

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

GT spec. B 6MT model

27.0 — 54.0 N (2.8 — 5.5 kgf, 6.1 — 12.1 lb)

If the total preload is not within the specifications,
adjust the side retainer shims.

6. COMPANION FLANGE

1) If rust or dirt is attached to the companion flange,
remove them.
2) Set a dial gauge at a companion flange surface
(mating surface of propeller shaft and companion
flange), and then measure the companion flange
runout.

Limit of runout:

0.08 mm (0.003 in)

3) Set the gauge inside of the companion flange,
and measure the runout.

Limit of runout:

0.08 mm (0.003 in)

4) If either runout exceeds the limit, move the
phase of companion flange and drive pinion 90°
each, and find the point where the runout is within
the limit.
5) If the runout exceeds the limit even after chang-
ing the phase, replace the companion flange and
recheck the runout.
6) If the runout exceeds the limit after replacing the
companion flange, the drive pinion may be assem-
bled incorrectly or bearing is faulty.

F: ADJUSTMENT

1. SIDE GEAR BACKLASH

Adjust the side gear backlash. <Ref. to DI-37, AS-
SEMBLY, Rear Differential (T-type).>

2. HYPOID DRIVEN GEAR BACKLASH

Adjust hypoid driven gear backlash. <Ref. to DI-37,
ASSEMBLY, Rear Differential (T-type).>

3. TOOTH CONTACT BETWEEN HYPOID 
DRIVEN GEAR AND DRIVE PINION

Adjust the tooth contact between hypoid driven
gear and drive pinion gear. <Ref. to DI-37, ASSEM-
BLY, Rear Differential (T-type).>

4. TOTAL PRELOAD

Adjust the side retainer shim. <Ref. to DI-37, AS-
SEMBLY, Rear Differential (T-type).>

DI-00117

DI-00360

DI-00361

DI-56

Rear Differential (VA-type)

DIFFERENTIALS

5. Rear Differential (VA-type)

A: REMOVAL

1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Shift the select lever or gear shift lever to neutral.
4) Release the parking brake.
5) Loosen the wheel nuts.
6) Lift up the vehicle.
7) Remove the wheels.
8) Drain the differential gear oil. <Ref. to DI-26, RE-
PLACEMENT, Differential Gear Oil.>
9) Remove the rear exhaust pipe and muffler. 
• 2.5 L SOHC non-turbo model
<Ref. to EX(H4SO)-8, REMOVAL, Rear Exhaust
Pipe.> <Ref. to EX(H4SO)-10, REMOVAL, Muf-
fler.>
• 2.5 L DOHC turbo model
<Ref. to EX(H4DOTC)-12, REMOVAL, Rear Ex-
haust Pipe.> <Ref. to EX(H4DOTC)-14, REMOV-
AL, Muffler.>
• 3.0 L DOHC non-turbo model
<Ref. to EX(H6DO)-7, REMOVAL, Rear Exhaust
Pipe.> <Ref. to EX(H6DO)-9, REMOVAL, Muffler.>
10) Remove the heat shield cover.

11) Remove the propeller shaft. <Ref. to DS-10,
REMOVAL, Propeller Shaft.>
12) Prepare the transmission jack and band.

13) Loosen the self-lock nuts which hold the rear
differential to rear crossmember.

14) Remove the DOJ of rear drive shaft from rear
differential.

15) Remove the nuts which hold the rear differen-
tial front member.

16) Support the rear differential with the transmis-
sion jack.

17) Remove the rear differential front member.
18) Secure the rear differential using band.

AT-01331

DI-00268

(A) Tire lever

(B) Bolt

DI-00269

DI-00287

(A)

(B)

DI-00362

DI-00273