Front Differential: Assembly

DIFFERENTIAL CASE ASSEMBLY
1. Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH). Insert the pinion shaft.
2. Install straight pin from reverse direction.
  
  Fig 1: Installing Straight Pin
  Courtesy of SUBARU OF AMERICA, INC.
3. 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.
4. 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.
5. Measurement of backlash (Selection of washer)
  1. Install SUBARU genuine axle shaft to differential case. (TURBO model)
  2. Measure the gear backlash with ST1 and ST2, and insert ST2 through the access window of the case.
    ST1 498247001 MAGNET BASE
    
    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 Backlash By Applying Pinion Tooth Between Bevel Gear Teeth
    Courtesy of SUBARU OF AMERICA, INC.
  3. If backlash is not as specified, select a washer from the table below.
  Fig 4: Washer Specifications
  Courtesy of SUBARU OF AMERICA, INC.
6. Using ST, install taper roller bearing.
  ST 398437700 DRIFT
  
  Fig 5: Installing Taper Roller Bearing Using Special Tool
  Courtesy of SUBARU OF AMERICA, INC.
SIDE RETAINER
1. Install bearing outer race to side retainer.
2. Install a new oil seal using the ST and hammer.
  ST 499797000 INSTALLER
  
  Fig 6: Installing Oil Seal Using Special Tool
  Courtesy of SUBARU OF AMERICA, INC.
3. Using the ST and hammer, install a new oil seal. (TURBO model)
  ST 18675AA000 INSTALLER
  
  Fig 7: Installing Oil Seal Using Special Tool
  Courtesy of SUBARU OF AMERICA, INC.
4. Install new O-ring.
  
  Fig 8: Installing O-Ring
  Courtesy of SUBARU OF AMERICA, INC.