Drive Pinion Shaft Assembly: Adjustment

Remove the liquid gasket from the mating surface completely.
Using the ST, install the drive pinion retainer to converter case.
ST1 18270KA020 SOCKET (E20)

NOTE: Do not confuse the three different-length bolts when installing.

Tightening torque:

43 N.m (4.4 kgf-m, 31.7 ft-lb)

Fig 1: Identifying Drive Pinion Retainer Different-Length Bolts
Courtesy of SUBARU OF AMERICA, INC.
Rotate the drive pinion several times using ST1 and ST2.
ST1 18667AA010 HOLDER

ST2 499787700 WRENCH

Fig 2: Rotating Drive Pinion With Holder And Wrench
Courtesy of SUBARU OF AMERICA, INC.
Adjust the drive pinion and hypoid driven gear backlash. Refer to , ADJUSTMENT , Front Differential Assembly.
Using the ST, remove the drive pinion retainer from converter case.
ST1 18270KA020 SOCKET (E20)
Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Then install the drive pinion retainer and rotate the drive pinion in both directions several times. Remove the drive pinion retainer and check the tooth contact pattern.
If the teeth contact is inappropriate, adjust the backlash or thickness of the shim. Refer to , ADJUSTMENT , Front Differential Assembly.

NOTE: After correction, wipe off the lead-free red dye.
- Correct tooth contact
  Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.)
  
  Fig 3: Identifying Toe Side And Heel Side Of Tooth
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- Face contact
  Check item: Backlash is too large.
  
  Contact pattern
  
  Fig 4: Identifying Face Contact
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  Corrective action: Increase thickness of pinion height adjusting washer according to the procedure for bringing drive pinion close to hypoid driven gear side.
  
  Fig 5: Identifying Increase Thickness Of Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
- Flank contact
  Check item: Backlash is too small.
  
  Contact pattern
  
  Fig 6: Identifying Flank Contact
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  Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear.
  
  Fig 7: Identifying Reduce Thickness Of Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
- Toe contact (inside contact)
  Check item: Teeth contact area is too small.
  
  Contact pattern
  
  Fig 8: Identifying Toe Contact (Inside Contact)
  Courtesy of SUBARU OF AMERICA, INC.
  
  Corrective action: Reduce the thickness of pinion height adjusting washer according to the procedure for bringing drive pinion away from hypoid driven gear side.
  
  Fig 9: Identifying Reduce Thickness Of Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
- Heel contact (outside end contact)
  Check item: Teeth contact area is too small.
  
  Contact pattern
  
  Fig 10: Identifying Heel Contact (Outside End Contact)
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  Corrective action: Increase the thickness of the pinion height adjusting washer according to the procedures for moving the drive pinion closer to the hypoid driven gear.
  
  Fig 11: Identifying Increase Thickness Of Pinion Height
  Courtesy of SUBARU OF AMERICA, INC.
If tooth contact is correct, mark the differential side retainer position and loosen. After fitting a new O-ring and oil seal, screw in the differential side retainer to the marked position.
Tighten the lock plate with specified torque.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 12: Identifying Lock Plate
Courtesy of SUBARU OF AMERICA, INC.