Drive Pinion: Installation

Check the projection (A) of the knock pins.
NOTE: When attached on the converter case side, install them on the drive pinion retainer side.

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Specification:

8.0 - 9.0 mm (0.31 - 0.35 in)

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Select the drive pinion washer.

Measure the dimension "A" of a new taper roller bearing (front) inner race.

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Measure the dimension "B" of a new taper roller bearing (rear) inner race.

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Measure the dimension "C" of the drive pinion spacer.

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Place the drive pinion retainer on the surface plate, and set the taper roller bearing (rear) inner race to the taper roller bearing (rear) outer race.
NOTE: Be careful not to tilt the taper roller bearing (rear) inner race when setting.

Measure the height "H1" from the end face of the taper roller bearing (rear) inner race to the surface plate.

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Set the taper roller bearing (front) inner race to the taper roller bearing (front) outer race.
NOTE: Be careful not to tilt the taper roller bearing (front) inner race when setting.

Using the ST, measure and record the height "H2" from the ST end face to the taper roller bearing (front) inner race.

Preparation tool:

ST: GAUGE (499575400)

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Using the following calculation, calculate an appropriate thickness "T1" of the drive pinion washer.
NOTE: Adjust using 1 - 3 pieces.

T1 = H1 - (A + B + C + H2 - 15 mm (0.6 in))

T1	Drive pinion washer thickness (mm (in))
H1	Measured value (mm (in)) of step (5)
A	Measured value (mm (in)) of step (1)
B	Measured value (mm (in)) of step (2)
C	Measured value (mm (in)) of step (3)
H2	Measured value (mm (in)) of step (7)
15 mm (0.6 in)	Thickness of ST (GAUGE)

Select the drive pinion shim.

Using the ST, measure the height "H3" from the ST end face to the drive pinion retainer mating surface.

Preparation tool:

ST: GAUGE (499575400)

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Using the following calculation, calculate the height "H4" from the transmission case mating surface of the converter case to the drive pinion retainer mating surface.

H4 = H3 - 15 mm (0.6 in)

H4	Height (mm (in)) from the transmission case mating surface of the converter case to the drive pinion retainer mating surface
H3	Measured value (mm (in)) of step (1)
15 mm (0.6 in)	Thickness of ST (GAUGE)

Place the converter case on the surface plate.

Measure the inner diameter "D1" of the differential side retainer installation hole of the converter case.

NOTE: Perform the measurement at the contact surface of the side bearing outer race.

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Using the following calculation, calculate the radius "R" of the differential side retainer installation hole.

R = D1/2

R	Differential side retainer installation hole radius (mm (in))
D1	Measured value (mm (in)) of step (4)

Prepare a proper round bar, and measure its diameter at several locations.
Mark locations with the same measured values and refer to the values as "D2".

Set the marked location on the installation hole of the differential side retainer, and measure the height "H5" from the top end of the other marked location to the surface plate.

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Using the following calculation, calculate the height "H6" from the bottom end of the differential side retainer installation hole to the transmission case mating surface of the converter case.

H6 = H5 - D2

H6	Height (mm (in)) from the bottom end of the differential side retainer installation hole to the transmission case mating surface of the converter case
H5	Measured value (mm (in)) of step (8)
D2	Measured value (mm (in)) of step (7)

Using the following calculation, calculate the distance "S" from the center of the front differential to the transmission case mating surface of the converter case.

S = R + H6

S	Distance (mm (in)) from the center of the front differential to the transmission case mating surface of the converter case
R	Calculated value (mm (in)) of step (5)
H6	Calculated value (mm (in)) of step (9)

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Using the following calculation, calculate an appropriate thickness "T2" of the drive pinion shim.
NOTE: Adjust using 1 - 3 pieces.

T2 = (S - H4 + H2 - 15 mm (0.6 in)) - 90.8 mm (3.57 in)

T2	Drive pinion shim thickness (mm (in))
S	Calculated value (mm (in)) of step (10)
H4	Calculated value (mm (in)) of step (2)
H2	Measured value (mm (in)) of assembly step 2. (7)
15 mm (0.6 in)	Thickness of ST (GAUGE)
90.8 mm (3.57 in)	Ideal distance from the front differential center to the drive pinion end surface

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Set the drive pinion shim.

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Press-fit the taper roller bearing (front) inner race using the ST1, ST2 and a press.
Preparation tool:

ST1: INSTALLER (899580100)

ST2: EXTENSION DRIVE SHAFT (927130000)

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Install the drive pinion spacer and drive pinion washer.
NOTE: Install the O-ring after checking and adjusting the tooth contact of hypoid gear set.

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Set the drive pinion.
CAUTION: Be careful not to damage the oil seal.

NOTE: Apply differential gear oil to the oil seal lip.

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Temporarily attach the taper roller bearing (rear) inner race and lock nut.
NOTE:
- Apply differential gear oil to the threaded portion of the drive pinion.
- Use the lock nut removed when disassembling.
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Set the differential case.
CAUTION: Be careful not to damage the attachment section of the differential side retainer.

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Set the side bearing outer race, and temporarily install the differential side retainers using the ST.
NOTE:
- Replace the O-ring with a new one after checking and adjusting the tooth contact of hypoid gear set.
- When there is no replacement of the side bearing inner race, do not confuse the left side and right side.
Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA021)

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Using the ST, install the drive pinion retainer.
NOTE: Apply liquid gasket and install the O-ring after checking and adjusting the tooth contact of hypoid gear set.

Preparation tool:

ST: SOCKET (E20) (18270KA020)

Tightening torque:

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

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Hypoid gear set backlash adjustment

Rotate the drive pinion ten times or more using ST1 and ST2.

Preparation tool:

ST1: HOLDER (498937110)

ST2: WRENCH (499787700)

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While rotating the drive pinion, loosen the differential side retainer RH using ST, and tighten the differential side retainer LH until the drive pinion does not rotate anymore.
NOTE: The backlash is "zero" when the drive pinion comes to the point where it does not rotate.

Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA020)

Return the differential side retainer LH by 3 teeth and secure it with the lock plate.

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Tighten until the differential side retainer RH does not rotate anymore.
CAUTION: Do not tighten with excessive force.
Rotate the drive pinion 2 or 3 times.
Tighten the differential side retainer RH a further 1-3/4 teeth.
NOTE: This sets the preload.

Fix the differential side retainer RH with the lock plate.

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Attach the ST to the converter case.
NOTE: The ST is a SUBARU genuine part.

Preparation tool:

ST: Axle shaft (38415AA070)

Install the ST to the drive pinion retainer, and wrap the drive pinion with cloth and pinch with vise pliers.

Using a tie-wrap or a wire, fix the vise pliers to the ST.

NOTE: Make sure the drive pinion does not move.

Preparation tool:

ST: COMPRESSOR SHAFT (18763AA000)

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Measure the backlash using ST, dial gauge (lever type) and magnet stand.

Preparation tool:

ST: PLATE (498255400)

Specification:

0.13 - 0.18 mm (0.005 - 0.007 in)

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If the backlash is outside the standard

NOTE: Turning the differential side retainer by one tooth changes the backlash approx. 0.05 mm (0.002 in).

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When the backlash is too small
Loosen the differential side retainer LH by the required numbers of teeth, and tighten the differential side retainer RH by the same numbers of teeth.
When the backlash is too large
Loosen the differential side retainer RH by the required numbers of teeth, and tighten the differential side retainer LH by the same numbers of teeth.

Remove the ST (compressor shaft) and vise pliers.

Checking and adjusting the tooth contact of hypoid gear set

Using the ST, remove the drive pinion retainer.

Preparation tool:

ST: SOCKET (E20) (18270KA020)

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Apply lead-free red dye evenly on the three to four teeth of the driven gear.

Using the ST, install the drive pinion retainer.

Tightening torque:

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

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Rotate the drive pinion back and forth several times using ST1 and ST2, and check the tooth contact pattern.
NOTE:
- If proper tooth contact is not obtained, readjust the backlash of hypoid gear set and drive pinion shim.
  For drive pinion shim adjustment, refer to the "ASSEMBLY". Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>DRIVE PINION>ASSEMBLY .
- Wipe off the lead-free red dye completely after the check and adjustment are completed.
Preparation tool:

ST1: HOLDER (18667AA010)

ST2: WRENCH (499787700)

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Correct tooth contact

Tooth contact pattern is slightly shifted toward toe side under no-load rotation. (When driving, it moves towards the heel side.)

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Face contact

Cause: Excessive backlash

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Adjustment: Loosen the differential side retainer RH by the required numbers of teeth, and tighten the differential side retainer LH by the same numbers of teeth.

Otherwise, adjust the drive pinion shim thickness and move the drive pinion to the driven gear side.

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Flank contact

Cause: Too small backlash

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Adjustment: Loosen the differential side retainer LH by the required numbers of teeth, and tighten the differential side retainer RH by the same numbers of teeth.

Otherwise, adjust the drive pinion shim thickness and separate the drive pinion from the driven gear.

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Toe contact (inside contact)

Cause: Teeth contact area is too small.

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Adjustment: Adjust the drive pinion shim thickness and separate the drive pinion from the driven gear.

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Heel contact (outside end contact)

Cause: Teeth contact area is too small.

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Adjustment: Adjust the drive pinion shim thickness and move the drive pinion to the driven gear side.

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Put alignment marks (A) on the converter case and differential side retainer.

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Install a new O-ring to the differential side retainer.
NOTE: Perform this procedure one side first, then the other side.
1. Using the ST, loosen the differential side retainer until the mounting groove of the O-ring appears.
  NOTE: Record the number of the turns loosened.
  
  Preparation tool:
  
  ST: WRENCH COMPL RETAINER (18658AA021)
2. Fit a new O-ring, and tighten the differential side retainer into the position before it was loosened.
  NOTE: Apply the differential gear oil to O-ring.
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Install the lock plate.
Tightening torque:

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

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Using the ST, remove the drive pinion retainer.
Preparation tool:

ST: SOCKET (E20) (18270KA020)

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Remove the lock nut using ST1, ST2 and ST3.
Preparation tool:

ST1: ADAPTER (499787500)

ST2: WRENCH (499787700)

ST3: HOLDER (498937110)

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Remove the drive pinion.

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Remove the drive pinion washer and drive pinion spacer.

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Install a new O-ring.
NOTE: Apply the differential gear oil to O-ring.

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Install the drive pinion spacer and drive pinion washer.

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Set the drive pinion.
CAUTION: Be careful not to damage the oil seal.

NOTE: Apply differential gear oil to the oil seal lip to prevent damage.

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Temporarily install the lock nut.
CAUTION: Be sure to use a new lock nut.

NOTE: Apply differential gear oil to the threaded portion of the drive pinion.

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Using the ST1, ST2, ST3 and a spring scale, tighten the lock nut by adjusting within the specified tightening torque so that the initial load of the drive pinion is within the specified range.

CAUTION:

Before checking the initial load, apply differential gear oil to the roller part of taper roller bearing, and rotate it several times to measure the value.
If the initial load exceeds the specification before the tightening torque reaches the lower limit, immediately stop the tightening.

Specification:

Initial load

7.3-23.1 N (0.74-2.36 kgf, 1.64-5.19 lbf)

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Preparation tool:

ST1: ADAPTER (499787500)

ST2: WRENCH (499787700)

ST3: HOLDER (498937110)

Tightening torque:

Calculation formula

T = 170 - 250 N.m (17.3-25.5 kgf-m, 125.4-184.4 ft-lb) x L/(72.2 mm (2.84 in) + L)

T: Tightening torque
L: Effective length of torque wrench

NOTE: If the effective length of the torque wrench used is unknown, consult the manufacturer of the torque wrench.

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Crimp the lock nut in 2 locations.
Install a new plug using ST1, ST2, ST3 and a press.
Preparation tool:

ST1: PRESS SNAP RING (499755602)

ST2: INSTALLER (398177700)

ST3: INSTALLER (899580100)

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Install the oil baffle.

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Install a new O-ring.
NOTE: Apply CVTF to the O-rings.

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Apply liquid gasket to the mating surface of the converter case as shown in the figure, and temporarily install the drive pinion retainer.
NOTE:
- Before applying liquid gasket, degrease the old liquid gasket seal surface of the drive pinion retainer and converter case.
- Install within 5 min. after applying liquid gasket.
Liquid gasket:

THREE BOND 1216J or equivalent

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Tighten the bolts securing the drive pinion retainer.
Special tool:

SOCKET (E20) (18270KA020)

Tightening torque:

43 N.m (4.4 kgf-m, 31.7 ft-lb)
Install the reverse brake. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>REVERSE BRAKE>INSTALLATION .