Front Differential: Installation

Install the differential assembly to the case, paying special attention not to damage the inside of the case (particularly, the differential side retainer contact surface).

Fig 1: Installing Differential Assembly To Case
Courtesy of SUBARU OF AMERICA, INC.
Install the new circlip to the axle shaft, insert the shaft into the differential assembly, and tap it into position with a plastic hammer. (Except TURBO model)
NOTE: If no play is felt, check whether the shaft is fully inserted. If shaft insertion is correct, replace the axle shaft.
1. Thrust play: 0.3 - 0.5 mm (0.012 - 0.020 in)
Wrap vinyl tape around the splined portion of the axle shaft. (Except TURBO model)
Install the O-rings from left and right side retainer.
Using ST, install the side retainers. Refer to REMOVAL .
ST 499787000 WRENCH ASSY
Adjust the front differential backlash. Refer to ADJUSTMENT .
Install the lock plate.
1. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
Fig 2: Installing Lock Plate
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Install a new seal pipe to the torque converter clutch case.

Fig 3: Installing Seal Pipe To Torque Converter Clutch Case
Courtesy of SUBARU OF AMERICA, INC.
Install the torque converter clutch case to transmission case. Refer to INSTALLATION .
Insert the inhibitor switch and transmission connector into stay.

Fig 4: Inserting Inhibitor Switch & Transmission Connector Into Stay
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Install the oil cooler pipes. Refer to INSTALLATION .
Install the oil charger pipe with O-ring. Refer to INSTALLATION .
Insert the input shaft while turning it lightly by hand and verify the protrusion amount.
1. Normal protrusion A: 50 - 55 mm (1.97 - 2.17 in)
Fig 5: Inserting Input Shaft
Courtesy of SUBARU OF AMERICA, INC.
Install the torque converter clutch assembly.
Refer to INSTALLATION .
Install the transmission assembly to the vehicle. Refer to INSTALLATION .