Drive Pinion: Installation

Install the front differential.

Set the differential case.

CAUTION: Be careful not to damage the attachment section of the differential side retainer.

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Temporarily install the differential side retainers using the ST.

NOTE:

Install the O-ring 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 and the release pressure pipe.

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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(A)	M10 x 54
(C)	M10 x 33
(E)	Release pressure pipe
(B)	M10 x 45
(D)	Drive pinion retainer

Hypoid gear set backlash adjustment

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

Preparation tool:

ST1: HOLDER (18667AA010)

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 doesn't rotate.

Preparation tool:

ST: WRENCH COMPL RETAINER (18658AA021)

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

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(A)

One tooth

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.
Further tighten the differential side retainer (RH) by 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)

Backlash:

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 (a) 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 release pressure pipe (A) and the drive pinion retainer (B).

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 and the release pressure pipe.

Preparation tool:

ST: SOCKET (E20) (18270KA020)

Tightening torque:

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

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(A)	M10 x 54
(B)	M10 x 45
(C)	M10 x 33
(D)	Drive pinion retainer
(E)	Release pressure pipe

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 the drive pinion shim adjustment procedure, refer to the "ASSEMBLY". Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>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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(A)	Toe side (inside)
(B)	Heel side (outside)

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 to the position where 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 differential gear oil to the threads of the differential side retainer and O-rings.

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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 release pressure pipe (A) and the drive pinion retainer (B).
Preparation tool:

ST: SOCKET (E20) (18270KA020)

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

Specification:

10.5 - 11.5 mm (0.41 - 0.45 in)

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

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Using a new gasket, install the oil pump.

NOTE: Apply CVTF to the threaded portion of the bolts and seat surface.

Tightening torque:

8.5 N.m (0.9 kgf-m, 6.3 ft-lb)

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(A)	Oil pump
(B)	Gasket
(C)	Drive pinion retainer

Install the oil baffle.

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

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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.
NOTE:
- Before applying liquid gasket, degrease the liquid gasket seal surfaces of the converter case and the drive pinion retainer.
- Be careful not to block the arrowed hole when applying liquid gasket.
- Install within 5 min. after applying liquid gasket.
Preparation items:

Liquid gasket: THREE BOND 1215B or equivalent

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Using the ST, install the drive pinion retainer and the release pressure pipe to the converter case.

Preparation tool:

ST: SOCKET (E20) (18270KA020)

Tightening torque:

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

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(A)	M10 x 54
(B)	M10 x 45
(C)	M10 x 33
(D)	Drive pinion retainer
(E)	Release pressure pipe

Select the primary pulley shim when the drive pinion retainer or converter case is replaced.

NOTE: It is not necessary when the primary pulley and secondary pulley are replaced.

Using the ST, measure the height "H1" from the ST end face to the primary pulley bearing catch surface.

NOTE: Measure at four points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

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(A)	Measurement surface

Using the ST, measure the height "H2" from the ST end face to the secondary pulley bearing catch surface.

NOTE: Measure at four points and calculate the average.

Preparation tool:

ST: GAUGE (499575400)

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(A)	Measurement surface

Using the following calculation, measure the dimension "B" from the primary pulley bearing catch surface to the secondary pulley bearing catch surface.

B = H1 - H2

B	Dimension (mm (in)) from the primary pulley bearing catch surface to the secondary pulley bearing catch surface
H1	Measured value (mm (in)) of step (1)
H2	Measured value (mm (in)) of step (2)

Using the following calculation and selection criteria table, select an appropriate thickness of the primary pulley shim.

NOTE: Adjust using 1 to 2 pieces.

C = A - B

C	Dimension difference (mm (in))
A	Calculated value (mm (in)) of removal step 2 (4)
B	Calculated value (mm (in)) of step (3)

Primary pulley shim selection criteria table for calculated values

Dimension difference (mm (in))	Thickness of primary pulley shim to be selected
0.281 -0.300 (0.01106-0.01181)	Select the shim 0.3 mm (0.012 in) thicker than the primary pulley shim before replacement.
0.181 -0.280 (0.00712-0.01102)	Select the shim 0.2 mm (0.008 in) thicker than the primary pulley shim before replacement.
0.081 -0.180 (0.00318-0.00708)	Select the shim 0.1 mm (0.004 in) thicker than the primary pulley shim before replacement.
0.080 --0.070 (0.00315--0.00275)	Select a new shim of the same thickness as the primary pulley shim before replacement.
-0.071 --0.170 (-0.00 279--0.00669)	Select the shim 0.1 mm (0.004 in) thinner than the primary pulley shim before replacement.
-0.171 --0.230 (-0.00673--0.00905)	Select the shim 0.2 mm (0.008 in) thinner than the primary pulley shim before replacement.
-0.231 --0.300 (-0.00909--0.01181)	Select the shim 0.3 mm (0.012 in) thinner than the primary pulley shim before replacement.

Install the primary pulley and secondary pulley. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>PRIMARY PULLEY AND SECONDARY PULLEY>INSTALLATION .