1996 SUBARU LEGACY Service Repair Manual

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Page 993 of 2890

SUBARU LEGACY 1996 Service Repair Manual G3M1035
(3) Install the differential case assembly into differential
carrier in the reverse order of disassembly.
G3M1045
(4) Fit the selected shims and O-ring on side bearing
retainer and install the

Page 994 of 2890

SUBARU LEGACY 1996 Service Repair Manual G3M1047
15) Re-check crown gear-to-pinion backlash.
Backlash:
0.10—0.20 mm (0.0039—0.0079 in)
G3M1048
16) Check the crown gear runout on its back surface, and
make sure pinion and crown gear rotat

Page 995 of 2890

SUBARU LEGACY 1996 Service Repair Manual TOOTH CONTACT PATTERN
Condition Contact pattern Adjustment
Correct tooth contact
Tooth contact pattern slightly shifted
towards toe under no load rotation.
(When loaded, contact pattern moves
toward h

Page 996 of 2890

SUBARU LEGACY 1996 Service Repair Manual G3M1050
19) Install rear cover and tighten bolts to specified torque.
Tightening torque:
29±5 N⋅m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
F: INSTALLATION
To install, reverse the removal sequence.
1) Insta

Page 997 of 2890

SUBARU LEGACY 1996 Service Repair Manual 3. Rear Differential Front Member
A: REMOVAL
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to“N”.
3) Release the parking brake.
4) Loosen wheel nuts.
5) Jack-

Page 998 of 2890

SUBARU LEGACY 1996 Service Repair Manual G3M1029
B: INSTALLATION
To install, reverse the removal sequence.
1) Position front member on body by passing it under park-
ing brake cable and securing to rear differential.
G3M0101
NOTE:
When insta

Page 999 of 2890

SUBARU LEGACY 1996 Service Repair Manual 1. Rear Differential
Symptom and possible cause Remedy
1. Oil leakage

1Worn, scratched, or incorrectly seated front or side oil seal.
Scored, battered, or excessively worn sliding surface of com-
pa

1. Rear Differential
Symptom and possible cause Remedy
1. Oil leakage

1Worn, scratched, or incorrectly seated front or side oil seal.
Scored, battered, or excessively worn sliding surface of com-
panion flange.Repair or replace.

2Clogged or damaged air breather. Clean, repair or replace.

3Loose bolts on differential spindle or side retainer, or incor-
rectly fitted O-ring.Tighten bolts to specified torque. Replace O-ring.

4Loose rear cover attaching bolts or damaged gasket. Tighten bolts to specified torque. Replace gasket and apply liquid
packing.

5Loose oil filler or drain plug. Retighten and apply liquid packing.

6Wear, damage or incorrectly fitting for spindle, side retainer
and oil seal.Repair or replace.
2. Seizure
Seized or damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be
repaired or replaced as required.

1Insufficient backlash for hypoid gear. Readjust or replace.

2Excessive preload for side, rear, or front bearing. Readjust or replace.

3Insufficient or improper oil used. Replace seized part and fill with specified oil to specified level.
3. Damage
Damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be repaired or
replaced as required.

1Improper backlash for hypoid gear. Replace.

2Insufficient or excessive preload for side, rear, or front bear-
ing.Readjust or replace.

3Excessive backlash for differential gear. Replace gear or thrust washer.

4Loose bolts and nuts such as crown gear bolt. Retighten.

5Damage due to overloading. Replace.
4. Noises when starting or shifting gears
Noises may be caused by differential assembly, universal joint, wheel bearing, etc. Find out what is actually making noise before dis-
assembly.

1Excessive backlash for hypoid gear. Readjust.

2Excessive backlash for differential gear. Replace gear or thrust washer.

3Insufficient preload for front or rear bearing. Readjust.

4Loose drive pinion nut. Tighten to specified torque.

5Loose bolts and nuts such as side bearing retainer attaching
bolt.Tighten to specified torque.
40
3-4DIAGNOSTICS
1. Rear Differential

Page 1000 of 2890

SUBARU LEGACY 1996 Service Repair Manual Symptom and possible cause Remedy
5. Noises when cornering

1Damaged differential gear. Replace.

2Excessive wear or damage of thrust washer. Replace.

3Broken pinion mate shaft. Replace.

4Seized

Symptom and possible cause Remedy
5. Noises when cornering

1Damaged differential gear. Replace.

2Excessive wear or damage of thrust washer. Replace.

3Broken pinion mate shaft. Replace.

4Seized or damaged side bearing. Replace.
6. Gear noises
Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken for noises
from differential assembly, be careful in checking them. Inspection methods to locate noises include coasting, accelerating, cruising,
and jacking-up all four wheels. Perform these inspections according to condition of trouble. When listening to noises, shift gears into
four wheel drive and fourth speed position, trying to pick up only differential noise.

1Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.

2Improper backlash for hypoid gear. Readjust.

3Scored or chipped teeth of hypoid gear. Replace hypoid gear set.

4Seized hypoid gear. Replace hypoid gear set.

5Improper preload for front or rear bearings. Readjust.

6Seized, scored, or chipped front or rear bearing. Replace.

7Seized, scored, or chipped side bearing. Replace.

8Vibrating differential carrier. Replace.
2. Propeller Shaft
Symptom and possible cause Remedy
1. Vibration of propeller shaft
Vibration is caused by propeller shaft during operation and is transferred to vehicle body. Generally vibration increase in proportion to
vehicle speed.

1Worn or damaged universal joint. Replace.

2Unbalanced propeller shaft due to bend or dent. Replace.

3Loose installation of propeller shaft. Retighten.

4Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
2. Tapping when starting and noise while cruising, caused by propeller shaft.

1Worn or damaged universal joint. Replace.

2Worn spline of sleeve yoke. Replace.

3Loose installation of propeller shaft. Retighten.

4Loose installation of joint. Replace.

5Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
NOTE:
Vibration while cruising may be caused by an unbalanced
tire, improper tire inflation pressure, improper wheel
alignment, etc.
41
3-4DIAGNOSTICS
1. Rear Differential - 2. Propeller Shaft

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