Front Differential Assembly: Assembly

WARNING: This page is about a different car, the 2001 Subaru Impreza. However, it is still accessible from the selected car via links, so may be relevant.

Install bevel gear and bevel pinion together with washers, and insert pinion shaft.
NOTE: Face the chamfered side of washer toward gear.

Fig 1: Installing Bevel Gear, Bevel Pinion & Pinion Shaft
Measure backlash between bevel gear and pinion. If it is not within specifications, install a suitable washer to adjust it.
NOTE: Be sure the pinion gear tooth contacts adjacent gear teeth during measurement.

ST1 498247001 MAGNET BASE

ST2 498247100 DIAL GAUGE

Standard backlash: 0.13-0.18 mm (0.0051-0.0071 in)

Fig 2: Measuring Backlash Between Bevel Gear And Pinion

Fig 3: Washer (38.1 X 50 X T) Chart
Align pinion shaft and differential case at their holes, and drive straight pin into holes from the hypoid driven gear side, using ST.
NOTE: Lock straight pin after installing.

ST 899904100 REMOVER

Fig 4: Aligning Pinion Shaft And Differential Case
Install roller bearing (40 x 80 x 19.75) to differential case.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 lmp ton).

NOTE: Be careful because roller bearing outer races are used as a set.

ST1 499277100 BUSH 1-2 INSTALLER

ST2 398497701 ADAPTER

Fig 5: Installing Roller Bearing (40 x 80 x 19.75) To Differential Case
Install hypoid driven gear to differential case using twelve bolts.
Tightening torque:
1. T: 62 N.m (6.3 kgf-m, 45.6 ft-lb)
Fig 6: Installing Hypoid Driven Gear To Differential Case