Front Differential Assembly: Assembly

DIFFERENTIAL CASE ASSEMBLY
1. Install the 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 Together With Washers
  Courtesy of SUBARU OF AMERICA, INC.
2. Measure the backlash between bevel gear and pinion. If it is not within specifications, install a suitable washer to adjust it. Refer to ADJUSTMENT , Front Differential Assembly.
  NOTE: Be sure the pinion gear tooth contacts adjacent gear teeth during measurement.
  
  ST1 498247001 MAGNET BASE
  
  ST2 498247100 DIAL GAUGE
  1. Standard backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in)
  Fig 2: Measuring Backlash Between Bevel Gear & Pinion
  Courtesy of SUBARU OF AMERICA, INC.
3. Align the pinion shaft and differential case at their holes, and drive the straight pin into holes from the hypoid driven gear side, using ST.
  NOTE: Lock the straight pin after installing.
  
  ST 899904100 REMOVER
  
  Fig 3: Aligning Pinion Shaft & Differential Case At Their Holes
  Courtesy of SUBARU OF AMERICA, INC.
4. Install the roller bearing to differential case.
  NOTE:
  - Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
  - Be careful because the roller bearing outer races are used as a set.
  ST1 499277100 BUSH 1--2 INSTALLER
  
  ST2 398497701 ADAPTER
  
  Fig 4: Installing Roller Bearing To Differential Case
  Courtesy of SUBARU OF AMERICA, INC.
5. Install the hypoid driven gear to differential case using twelve bolts.
  1. Tightening torque: 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.
6. Set the drive axle shaft into differential case and hold it using outer spring. Measure the shaft to case clearance to check if it is within specifications using thickness gauge. (Non-TURBO model)
  NOTE: Replace the snap ring with suitable one, if the measurement is not within specifications.
  
  Fig 6: Snap Ring Thickness Chart
  Courtesy of SUBARU OF AMERICA, INC.
  1. Clearance 0 - 0.2 mm (0 - 0.008 in)
  Fig 7: Identifying Clearance
  Courtesy of SUBARU OF AMERICA, INC.
SIDE RETAINER
1. Install a new oil seal. (Non-TURBO model)
  ST 49979700 INSTALLER
  
  Fig 8: Identifying ST 49979700 Installer
  Courtesy of SUBARU OF AMERICA, INC.
2. Install a new oil seal. (TURBO model)
  ST 18675AA000 DIFFERENTIAL OIL SEAL INSTALLER
  
  Fig 9: Identifying ST 18675AA000 Differential Oil Seal Installer
  Courtesy of SUBARU OF AMERICA, INC.
3. Install a new O-ring.
  NOTE: Do not stretch or damage the O-ring.
  
  Fig 10: Installing O-Ring
  Courtesy of SUBARU OF AMERICA, INC.