1996 SUBARU LEGACY differential

G3M0083
3) Adjusting drive pinion height
Adjust drive pinion height with shim installed between rear
bearing cone and the back of pinion gear.
(1) Install ST1, ST2 and ST3, as shown in the figure,
and apply the specified preload on the bearings. to 2).> Adjusting preload for front and rear bearings
NOTE:
At this time, install a pinion height adjusting shim which is
temporarily selected or the same as that used before.
G3M0263
(2) Measure the clearance N between the end of ST3
and the end surface of ST1 by using a thickness gauge.
NOTE:
Make sure there is no clearance between the case and
ST3.
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
ST3 398507701 DIFFERENTIAL CARRIER GAUGE
(3) Obtain the thickness of pinion height adjusting shim
to be inserted from the following formula, and replace
the temporarily installed shim with this one.
T=To+N(Hx0.01) 0.20 (mm)
Where:
T = Thickness of pinion height adjusting shim (mm)
To = Thickness of shim temporarily inserted (mm)
N = Reading of thickness gauge (mm)
H = Figure marked on drive pinion head
(Example of calculation)
To = 2.20 + 1.20 = 3.40 mm
N = 0.23 mmH=+1,
T = 3.40 + 0.23 0.01 0.20 = 3.42
Result: Thickness = 3.42 mm
Therefore use the shim 383605200.
Pinion height adjusting shim thicknessPart No. Thickness mm (in)
383495200
383505200
383515200
383525200
383535200
383545200
383555200
383565200
383575200
383585200
383595200
383605200
383615200
383625200
383635200
383645200
383655200
383665200
383675200
3836852003.09 (0.1217)
3.12 (0.1228)
3.15 (0.1240)
3.18 (0.1252)
3.21 (0.1264)
3.24 (0.1276)
3.27 (0.1287)
3.30 (0.1299)
3.33 (0.1311)
3.36 (0.1323)
3.39 (0.1335)
3.42 (0.1346)
3.45 (0.1358)
3.48 (0.1370)
3.51 (0.1382)
3.54 (0.1394)
3.57 (0.1406)
3.60 (0.1417)
3.63 (0.1429)
3.66 (0.1441)
29
3-4SERVICE PROCEDURE
2. Rear Differential

G3M0084
4) Install the selected pinion height adjusting shim on drive
pinion, and press the rear bearing cone into position with
ST.
ST 398177700 INSTALLER
G3M1039
5) Insert drive pinion
1into differential carrier
4, install
the previously selected bearing preload adjusting spacer

2
and washer
3.
G3M0085
6) Press-fit front bearing cone into case with ST1, ST2 and
ST3.
ST1 398507703 DUMMY COLLAR
ST2 399780104 WEIGHT
ST3 899580100 INSTALLER
G3M0719
7) Insert spacer, then press-fit pilot bearing with ST1 and
ST2.
ST1 399780104 WEIGHT
ST2 899580100 INSTALLER
G3M0087
8) Fit a new oil seal with ST.
NOTE:
Press-fit until end of oil seal is 1 mm (0.04 in) inward
from end of carrier.
Apply grease between the oil seal lips. [W2E0] 1).>
ST 498447120 OIL SEAL INSTALLER
30
3-4SERVICE PROCEDURE
2. Rear Differential

G3M0720
9) Press-fit companion flange with ST1 and ST2.
CAUTION:
Be careful not to damage bearing.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT
G3M1052
10) Install self-locking nut. Then tighten it with ST.
ST 498427200 FLANGE WRENCH
Tightening torque:
181±15 N⋅m (18.5±1.5 kg-m, 134±11 ft-lb)
G3M0069
11) Install crown gear on differential case.
Tightening Torque:
103±10 N⋅m (10.5±1.0 kg-m, 76±7 ft-lb)
NOTE:
Tighten diagonally while tapping the bolt heads.
G3M1041
12) Before installing side bearing, measure the bearing
width by using a dial gauge, ST1 and ST2.
Standard bearing width:
20.00 mm (0.7874 in)
NOTE:
Set the dial gauge needle to zero, using a standard bear-
ing or block of specified height in advance.
ST1 398227700 WEIGHT
ST2 398237700 GAUGE
G3M0091
13) Press side bearing cone onto differential case with
ST1.
ST1 398487700 DRIFT
31
3-4SERVICE PROCEDURE
2. Rear Differential

G3M1043
B3M0134A
14) Adjusting side bearing retainer shims
(1) The drive gear backlash and side bearing preload
can be determined by the side bearing retainer shim
thickness.
(2) When replacing differential case, differential carrier,
side bearing and side bearing retainer, obtain the right
and left retainer shim thickness from the following for-
mulas.
T
1(Left) = (A + C + G1D) x 0.01 + 0.76E (mm)
T
2(Right) = (B+D+G2) x 0.01 + 0.76F (mm)
T
1&T2: Thickness of left and right side bearing
retainer shim (mm)
A & B : Number marked on differential carrier
C & D : Number marked on differential case
E & F : Difference of width of left and right side
bearing from standard width 20.0 mm,
expressed in a unit of 0.01 mm. For
example, if the bearing measured width
is 19.89 mm, value of E or F is as follows.
20.0019.89 = 0.11 (E or F)
G
1&G2: Number marked on side bearing retainer
If a number is not marked, regard it as zero.
NOTE:
Use several shims to obtain the calculated thickness.
Side bearing retainer shim thicknessPart No. Thickness mm (in)
383475201 0.20 (0.0079)
383475202 0.25 (0.0098)
383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
32
3-4SERVICE PROCEDURE
2. Rear Differential

Example of calculation
Ex. 1
A=5,B=5,C=3,D=3,G
1=4,G2=1,
E = 0.10 mm, F = 0.15 mm
Left side
T
1=(A+C+G1D) x 0.01 + 0.76E
=(5+3+43) x 0.01 + 0.760.10
= 0.09 + 0.760.10 = 0.75 mm
The correct shims are as follows:
Thickness Q’ty
0.25 x 1 = 0.25
0.50 x 1 = 0.50
Total shim thickness = 0.75 mm
Right side
T
2=(B+D+G2) x 0.01 + 0.76F
=(5+3+1)x0.01 + 0.760.15
= 0.09 + 0.760.15
= 0.70 mm
The correct shims are as follows:
Thickness Q’ty
0.20 x 1 = 0.20
0.50 x 1 = 0.50
Total shim thickness = 0.70 mm
Ex. 2
A=2,B=3,C=0,D=3,G
1=2,G2=3,
E = 0.22 mm, F = 0.10 mm
Left side
T
1=(A+C+G1D) x 0.01 + 0.76E
=(2+0+23) x 0.01 + 0.760.22
= 0.01 + 0.760.22
= 0.55 mm
The correct shims are as follows:
Thickness Q’ty
0.25 x 1 = 0.25
0.30 x 1 = 0.30
Total shim thickness = 0.55 mm
Right side
T
2=(B+D+G2) x 0.01 + 0.76F
=(3+3+3)x0.01 + 0.760.10
= 0.09 + 0.760.10
= 0.75 mm
The correct shims are as follows:
Thickness Q’ty
0.25 x 1 = 0.25
0.50 x 1 = 0.50
Total shim thickness = 0.75 mm
33
3-4SERVICE PROCEDURE
2. Rear Differential

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 them on differential carrier with the
arrow mark on the retainer directed as shown in figure.
CAUTION:
Be careful that side bearing cup is not damaged by
bearing roller.
G3M1046
(5) Tighten side bearing retainer bolts.
Tightening Torque:
10.3±1.5 N⋅m (1.05±0.15 kg-m, 7.6±1.1 ft-lb)
G3M1047
(6) Measure the crown gear-to-drive pinion backlash.
Set magnet base on differential carrier. Align contact point
of dial gauge with tooth face of crown gear, and move
crown gear while holding drive pinion still. Read value indi-
cated on dial gauge.
Backlash:
0.10 — 0.20 mm (0.0039 — 0.0079 in)
(7) At the same time, measure the turning resistance
of drive pinion. Compared with the resistance when
differential case is not installed, if the increase of the
resistance is not within the specified range, readjust
side bearing retainer shims.
Turning resistance increase:
0.1 — 0.6 N⋅m (1 — 6 kg-cm, 0.9 — 5.2 in-lb)
NOTE:
If measured backlash is not within specified range, repeat
steps (1) thru (7).
34
3-4SERVICE PROCEDURE
2. Rear Differential

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 rotate smoothly.
Limit of runout:
0.05 mm (0.0020 in)
17) Checking and adjusting tooth contact of crown gear
(1) Apply an even coat of red lead on both sides of
three or four teeth on the crown gear. Check the con-
tact pattern after rotating crown gear several revolu-
tions back and forth until a definite contact pattern
appears on the crown gear.
(2) When the contact pattern is incorrect, readjust
according to the instructions given in“TOOTH CON-
TACT PATTERN”.
NOTE:
Be sure to wipe off red lead completely after adjustment is
completed.
18) If proper tooth contact is not obtained, once again
adjust the drive pinion height and the differential side bear-
ing preload (mentioned above) and the hypoid gear back-
lash.
35
3-4SERVICE PROCEDURE
2. Rear Differential

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 heel.)
B3M0317A
Face contact
Backlash is too large.This may cause noise and chipping at
tooth ends.
B3M0319
Increase thickness of drive pinion height
adjusting shim in order to bring drive
pinion closer to crown gear center.
B3M0323
Flank contact
Backlash is too small.This may cause noise and stepped wear
on surfaces.
B3M0320
Reduce thickness of drive pinion height
adjusting shim in order to move drive
pinion away from crown gear.
B3M0324
Toe contact
Contact area is small.This may cause chipping at toe ends.
B3M0321
Adjust as for flank contact.
B3M0324
Heel contact
Contact area is small.This may cause chipping at heel ends.
B3M0322
Adjust as for face contact.
B3M0323
: Adjusting direction of drive pinion
: Adjusting direction of crown gear
36
3-4SERVICE PROCEDURE
2. Rear Differential