Differential Case Assembly

WARNING: This page is about a different car, the 2003 Subaru Outback, 2003 Subaru Legacy, and 2003 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.

Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH).
Insert the pinion shaft.
Install straight pin from reverse direction.

Fig 1: Installing Straight Pin From Reverse Direction
Courtesy of SUBARU OF AMERICA, INC.
Install the washer and differential bevel gear to the differential case (LH). Then put the case over the differential case (RH), and connect both cases.
Install the crown gear and secure by tightening the bolt.
1. Standard tightening torque: 62 N.m (6.3 kgf-m, 45.6 ft-lb)
Fig 2: Installing Crown Gear
Courtesy of SUBARU OF AMERICA, INC.

Measurement of backlash (Selection of washer)

Measure the gear backlash with ST1 and ST2, and insert ST2 through the access window of the case.
1. ST1 498247001 MAGNET BASE
2. ST2 498247100 DIAL GAUGE
NOTE:
- Measure the backlash by applying a pinion tooth between two bevel gear teeth.
- Fix bevel pinion gear in place with a screwdriver or similar tool when measuring.
1. Standard value: 0.13-0.18 mm (0.0051-0.0071 in)
Fig 3: Measuring Gear Backlash
Courtesy of SUBARU OF AMERICA, INC.

If backlash is not as specified, select a washer from the table below.

WASHER

Part No.	Thickness mm (in)
803038021	0.95 (0.037)
803038022	1.00 (0.039)
803038023	1.05(0.041)

Using ST, install taper roller bearing.
1. ST 398437700 DRIFT
Fig 4: Installing Taper Roller Bearing
Courtesy of SUBARU OF AMERICA, INC.