Front Differential Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.

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 And Bevel Pinion Together With Washers
Courtesy of SUBARU OF AMERICA, INC.
Measure backlash between bevel gear and pinion. If it is not within specifications, install a suitable washer to adjust it. Refer to ADJUSTMENT under FRONT DIFFERENTIAL ASSEMBLY .
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
Courtesy of SUBARU OF AMERICA, INC.
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 3: Driving Straight Pin Into Holes From Hypoid Driven Gear Side
Courtesy of SUBARU OF AMERICA, INC.
Install roller bearing 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 to use roller bearing outer races as a set.

ST1 499277100: BUSHING 1-2 INSTALLER

ST2 398497701: ADAPTER

Fig 4: Installing Roller Bearing To Differential Case
Courtesy of SUBARU OF AMERICA, INC.
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 5: Installing Hypoid Driven Gear To Differential Case
Courtesy of SUBARU OF AMERICA, INC.