Front Differential Assembly: Adjustment

Using the ST, screw-in the retainer until resistance is felt.
NOTE: RH side should be screwed-in more than LH side.

ST 18658AA020 WRENCH COMPL RETAINER

Fig 1: Identifying Side Retainer With Wrench COMPL Retainer
Courtesy of SUBARU OF AMERICA, INC.
Remove the remaining liquid gasket from the mating surface completely.
Using the ST, install the drive pinion assembly 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 2: Identifying Drive Pinion Assembly With Different-Length Bolts
Courtesy of SUBARU OF AMERICA, INC.
Rotate the drive pinion shaft more than ten times using ST1 and ST2.
ST1 18667AA010 HOLDER

ST2 499787700 WRENCH

Fig 3: Rotating Drive Pinion Shaft Using Holder And Wrench
Courtesy of SUBARU OF AMERICA, INC.
While rotating the pinion shaft, keep tightening the retainer LH, and loosening the retainer RH until the pinion shaft no longer be turned. When pinion shaft no longer turns, backlash is "zero".
After the "zero" state is established, loosen the retainer LH by 3 notches and secure it with the lock plate. Loosen the retainer RH and retighten until it stops. Rotate the drive pinion 2 or 3 times. Tighten the retainer RH further 1-3/4 notches. This sets the preload. Finally, secure the retainer with its lock plate.

Fig 4: Identifying Lock Plate On Retainer
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Turning the retainer by every one tooth changes the backlash approx. 0.05 mm (0.0020 in).

Fig 5: Identifying Turning Distance Of One Tooth
Courtesy of SUBARU OF AMERICA, INC.
Insert the two Subaru genuine axle shaft into differential case.
Part No. 38415AA070 AXLE SHAFT
Wrap the drive shaft pinion shaft with cloth and pinch with vise pliers. Install the installation bolt into the bolt hole of secondary pulley and secure the bolt and vise pliers using a band or wire. Make sure the drive pinion shaft does not move.

Fig 6: Identifying Secondary Pulley Installation Bolt
Courtesy of SUBARU OF AMERICA, INC.
Check the backlash is within specification using ST1, ST2 and ST3.
ST1 498255400 PLATE

ST2 498247100 DIAL GAUGE

ST3 498247001 MAGNET BASE

Backlash:

0.13 - 0.18 mm (0.005 - 0.007 in)

Fig 7: Checking Backlash Using Plate, Dial Gauge And Magnet Base
Courtesy of SUBARU OF AMERICA, INC.
Adjust the teeth contact of the front differential and drive shaft. Refer to , ADJUSTMENT , Drive Pinion Shaft Assembly.