2001 impreza service manual quick reference index
Contents
1. DIFFERENTIALS 10 Remove propeller shaft CAUTION When removing propeller shaft pay attention not to damage the sliding surfaces of rear drive shaft extension spline oil seal and sleeve yoke NOTE e Prepare an oil can and cap since the transmis sion oil flows out from the extension at removing propeller shaft e Insert the cap into the extension to prevent trans mission oil from flowing out immediately after re moving the propeller shaft e If extension cap is not available cover the open ing with a vinyl bag in order to prevent transmission gear oil or ATF leakage S3M0033A 11 Remove heat sealed cover 12 Remove clamps and bracket of parking brake cable Heat sealed cover FN es ET fal l i eae DI 25 REAR DIFFERENTIAL FOR T TYPE DIFFERENTIALS 13 Remove DOJ of rear drive shaft from rear dif ferential using ST lt Ref to DI 59 REPLACE MENT Rear Differential Side Oil Seal gt ST 28099PA100 DRIVE SHAFT REMOVER A B3M1628B 14 Secure rear drive shaft to rear crossmember using wire G3M1022 15 Remove lower differential bracket AOV Lower ae 7 differential ie i Ke 16 Support rear differential with transmission jack Transmission SN jack L TX G3M005 17 Remove self locki2. G3M0043 REAR DIFFERENTIAL SIDE OIL SEAL DIFFERENTIALS 7 Remove the DOJ from the rear differential by using ST CAUTION When removing the DOJ from the rear differen tial fit ST to the bolts as shown in figure so as not to damage the side bearing retainer ST 208099PA100 DRIVE SHAFT REMOVER DR0006 A Bolt 9 Remove rear drive shaft to rear crossmember using wire G3M1022 10 Remove nut of protector ST 398527700 PULLER ASSY G3M1023 11 Drive in a new side oil seal with ST CAUTION Apply chassis grease between the oil seal lips DRIFT ST 398437700 G3M1024 12 Insert the DOJ into rear differential 1 Install ST to rear differential ST 28099PA090 SIDE OIL SEAL PROTEC DROOO7 2 Install the spline shaft until the spline portion is inside the side oil real using ST ST 28099PA090 SIDE OIL SEAL PROTEC TOR MIF BSS 4 l LELIA J Na Y G3M1026 a LU od My eV K S DI 60 REAR DIFFERENTIAL SIDE OIL SEAL 3 Remove ST ST 28099PA090 SIDE OIL SEAL PROTEC TOR 13 Hereafter re assemble in reverse order of dis assembly 2 VA TYPE 1 Disconnect ground terminal from battery Move select lever or gear shift lever to N Release the parking brake Loosen both wheel nuts 5 Jack up the vehicle and support it with rigid racks 6 Remove wheels 7 Rem
3. G3M1047 DI 55 REAR DIFFERENTIAL FOR VA TYPE DIFFERENTIALS 3 CROWN GEAR RUNOUT Using a dial gauge check the crown gear runout Crown gear runout Less than 0 05 mm 0 0020 in If the crown gear runout exceeds 0 05 mm 0 0020 in replace the crown gear S3M0525 4 TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION Inspect tooth contact between crown gear and drive pinion lt Ref to DI 46 ASSEMBLY Rear Differential for VA type gt F ADJUSTMENT 1 SIDE GEAR BACKLASH Adjust side gear backlash lt Ref to DI 46 ASSEMBLY Rear Differential for VA type gt 2 CROWN GEAR BACKLASH Adjust crown gear backlash lt Ref to DI 46 ASSEMBLY Rear Differential for VA type gt 3 TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION Adjust the tooth contact between crown gear and drive pinion gear lt Ref to DI 46 ASSEMBLY Rear Differential for VA type gt DI 56 REAR DIFFERENTIAL FRONT OIL SEAL 6 Rear Differential Front Oil Seal A REPLACEMENT 1 Set the vehicle on the lift 2 Disconnect ground cable from battery Move select lever or gear shift lever to N Release the parking brake Remove oil drain plug and drain gear oil Er EET 3 4 5 DR0003 A Filler plug B Drain plug 6 Install oil drain plug NOTE Apply fluid packing to drain plug in T type e VA type uses a new aluminum gasket Tightening torque T t
4. 18 19 18 12 H3M1663A 1 Pinion crown gear set 13 Lock plate 25 Stud bolt 2 Pinion height adjusting shim 14 Side bearing 26 Gasket 3 Rear bearing 15 O ring 27 Oil filler plug 4 Bearing preload adjusting spacer 16 Axle shaft holder 28 Oil drain plug 5 Bearing preload adjusting washer 17 Side oil seal 29 Rear cover 6 Differential carrier 18 Side gear thrust washer 7 Front bearing 19 Side gear Tightening torque N m kgf m ft lb 8 Collar 20 Pinion mate gear T1 25 2 5 18 1 9 Pilot bearing 21 Pinion shaft lock pin T2 25 2 5 18 1 10 Front oil seal 22 Differential case T3 34 3 5 25 3 11 Companion flange 23 Pinion mate shaft T4 62 6 3 45 6 12 Self locking nut 24 Air breather cap T5 188 19 2 139 DI 8 GENERAL DESCRIPTION DIFFERENTIALS 4 REAR DIFFERENTIAL MOUNTING SYS TEM 9 0 cro ENE Ko N a N SAO C DR0002 1 Differential front member 7 Stopper Tightening torque N m kgf m ft lb 2 Plate 8 Dynamic damper T1 20 2 0 14 5 3 Crossmember 9 Differential mount bracket T2 33 3 4 24 3 4 Differential rear member 10 Differential mount front cover T3 65 6 6 47 9 5 Differential mount lower bracket T4 70 7 1 51 6 TURBO model T5 90 9 2 66 4 6 Differential mount l
5. Apply fluid packing to drain plug in T type s VA type uses a new aluminum gasket Fluid packing THREE BOND 1105 or equivalent Tightening torque T type 49 0 N m 5 0 kgf m 36 2 ft Ib VA type 34 N m 3 5 kgf m 25 3 ft Ib DI 23 FRONT DIFFERENTIAL DIFFERENTIALS 3 Front Differential A NOTE 1 AT MODEL Refer to AUTOMATIC TRANSMISSION in sepa rate publication AUTOMATIC TRANSMISSION for Front Differential 2 MT MODEL For front differential of manual transmission refer to MT section lt Ref to MT 102 Front Differential Assembly gt DI 24 REAR DIFFERENTIAL FOR T TYPE 4 Rear Differential for T type A REMOVAL 1 Set the vehicle on the lift 2 Disconnect ground terminal from battery Move select lever or gear shift lever to N Release the parking brake Loosen wheel nuts Jack up vehicle and support it with sturdy racks Remove wheels 8 Remove rear exhaust pipe and muffler Non turbo model without OBD lt Ref to EX SOHCw oOBD 13 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX SOHCw oOBD 14 REMOVAL Muffler gt Non turbo model with OBD lt Ref to EX SOHC 11 REMOVAL Rear Exhaust Pipe and lt Ref to EX SOHC 12 REMOVAL Muffler gt Turbo model lt Ref to EX DOHC TURBO 13 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX DOHC TURBO 14 REMOVAL Muffler gt 9 Remove front cover of rear differential mount EE EE EE 3 4 5 6 7
6. 3 HOLDER 399527703 4 ADAPTER 398497701 5 BOLT 899520107 6 NUT 021008000 e For T type B3M1916 398227700 WEIGHT DI 16 e Used for installing side bearing e For T type GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 28099PA090 OIL SEAL PROTEC Used for installing rear drive shaft into rear dif TOR ferential e For protecting oil seal B3M1917 398237700 GAUGE e Used for installing side bearing e For T type B3M1918 28099PA100 DRIVE SHAFT e Used for removing rear drive shaft from rear REMOVER differential e For T type B3M1919 498175500 INSTALLER e Used for installing rear bearing cone e For VA type B3M1920 DI 17 DIFFERENTIALS GENERAL DESCRIPTION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499785500 WRENCH ASSY e Used for removing and installing side oil seal holder e For VA type B3M1921 498447100 DRIFT e Used for installing oil seal e For VA type B3M1922 399520105 SEAT e Used for removing side bearing cone e Used with PULLER SET 899524100 e For VA type B3M1923 399703602 PULLEY ASSY e Used for removing companion flange B3M1930 DI 18 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498485400 DRIFT e Used for installing side bearing cone e For VA type B3M1924 498505501 DIFFERENTIAL e Used for adjust
7. e Prepare an oil can and cap since the transmis sion oil flows out from the extension at removing propeller shaft e Insert the cap into the extension to prevent trans mission oil from flowing out immediately after re moving the propeller shaft S3M0033A 11 Remove heat sealed cover 12 Remove clamps and bracket of parking brake cable Heat sealed cover WV ia RI fol 1 i Vee DI 40 REAR DIFFERENTIAL FOR VA TYPE 13 Remove DOJ of rear drive shaft from rear dif ferential lt Ref to DI 59 REPLACEMENT Rear Differential Side Oil Seal gt using wire L 3M0257 14 Secure rear drive shaft to rear crossmember G3M0046 15 Remove lower differential bracket all Ee z bracket H3M1273A 16 Support rear differential with transmission jack Pa s os Gy TAN i 1 Transmission N jack 5 o lt A N G3M0055 DIFFERENTIALS 17 Remove self locking nuts connecting rear dif ferential to rear crossmember gt 18 Remove bolts which secure rear differential front member to bolts B NOTE Support front member with the use A first then re moval bolts B B3M0657C A Bolt A B Bolt B 19 Remove bolt A 20 While slowly lowering transmission jack move rear differential forward and remove bolts from
8. 2 mm 2 213 in 56 4 mm 2 220 in 383695203 383695204 56 8 mm 2 236 in 383695205 56 6 mm 2 228 in 57 0 mm 2 244 in 383695206 Part No 57 2 mm 2 252 in Length 383705200 383715200 2 59 mm 0 1020 in 2 57 mm 0 1012 in 383725200 2 55 mm 0 1004 in 383735200 2 53 mm 0 0996 in 383745200 2 51 mm 0 0988 in 383755200 2 49 mm 0 0980 in 383765200 2 47 mm 0 0972 in 383775200 2 45 mm 0 0965 in 383785200 2 43 mm 0 0957 in 383795200 2 41 mm 0 0949 in 383805200 2 39 mm 0 0941 in 383815200 2 37 mm 0 0933 in 383825200 2 35 mm 0 0925 in 383835200 2 33 mm 0 0917 in 383845200 DI 4 2 31 mm 0 0909 in GENERAL DESCRIPTION DIFFERENTIALS Part No Thickness 383495200 3 09 mm 0 1217 in 383505200 3 12 mm 0 1228 in 383515200 3 15 mm 0 1240 in 383525200 3 18 mm 0 1252 in 383535200 3 21 mm 0 1264 in 383545200 3 24 mm 0 1276 in 383555200 3 27 mm 0 1287 in 383565200 3 30 mm 0 1299 in 383575200 3 33 mm 0 1311 in Pinion height adjusting shim 383585200 3 36 mm 0 1323 in 383595200 3 39 mm 0 1335 in 383605200 3 42 mm 0 1346 in 383615200 3 45 mm 0 1358 in 383625200 3 48 mm 0 1370 in 383635200 3 51 mm 0 1382 in 383645200 3 54 mm 0 1394 in 383655200 3 57 mm 0 1406 in 383665200 3 60 mm 0 1417 in 383675200 3 63 mm 0
9. 3 kgf 2 9 7 3 Ib at companion flange bolt hole Adjusting preload for front and rear bearings NOTE At this time install an original pinion height adjust ing shim ST1 498447150 DUMMY SHAFT ST2 32285AA000 DUMMY COLLAR ST3 498505501 DIFFERENTIAL CARRIER GAUGE S3M0518A A Pinion height adjusting shim 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 498447150 DUMMY SHAFT DIFFERENTIAL CARRIER GAUGE ST2 498505501 H3M1309B 3 Obtain the thickness of pinion height adjust ing washer to be inserted from the following for mula and replace the temporarily installed shim with this one NOTE Use 1 to 3 shims as required for adjustment T To N 0 05 mm where T Thickness of pinion height adjusting shim mm To Thickness of shim originally installed mm N Reading of thickness gauge mm H Figure marked on drive pinion head Example of calculation To 0 15 mm N 0 1 mm Ts 0 15 0 1 0 05 0 2 mm Result Thickness 0 2 mm Therefore use the 32295AA220 Pinion height adjusting shim Part No Thickness mm in 32295AA200 0 150 0 0059 32295AA210 0 175 0 0069 32295AA220 0 200 0 0079 32295AA230 32295AA250 0 275 0 0108 0 225 0 0089 3
10. Be sure to wipe off red lead completely after adjust ment is completed DI 52 REAR DIFFERENTIAL FOR VA TYPE DIFFERENTIALS 20 If proper tooth contact is not obtained once 3 Hypoid gear backlash on S drive SW SE the Es Backlash ential side bearing preload already mentione S and the aea eet eer er y 0 10 0 15 mm 0 0039 0 0059 in 1 Drive pinion height ST1 498447150 DUMMY SHAFT ST2 498505501 DIFFERENTIAL GAUGE ST2 Nee H3M1309B T To N 0 05 mm where T Thickness of pinion height adjusting shim mm To Thickness of shim originally installed mm N Reading of thickness gauge mm 2 Differential side bearing preload Screw in side left side holder until light contact is made with ST Back off side left side holder approximately 1 1 2 teeth of holder and tighten left side holder by approximately 2 teeth approximately 1 1 2 1 2 teeth Back off amount of side left side holder 1 2 tooth This 1 2 tooth gives preload ST 499785500 WRENCH G3M0064 DI 53 REAR DIFFERENTIAL FOR VA TYPE DIFFERENTIALS TOOTH CONTACT PATTERN Condition Correct tooth contact Tooth contact pattern slightly shifted towards toe under no load rotation When loaded contact pattern moves toward heel Face contact Backlash is too large Contact pattern Heel side Wa Ed ER G3M0098A This may cause noise and chi
11. S3M0509 12 Press side bearing cone onto differential case with ST ST 498485400 DRIFT G3M0091 13 Assemble holders 1 Install oil seal into right and left holders DRIFT ST 498447100 ST S3M0522A DI 50 REAR DIFFERENTIAL FOR VA TYPE 2 Install bearing race into right and left hold ers ST 398477702 BEARING OUTER RACE DRIFT G3M0093 3 Install the differential case assembly into dif ferential carrier in the reverse order of disas sembly G3M0065 14 Perform adjustment of backlash of pinion crown gear set and adjustment of preload of differential side bearing 1 Turn drive pinion with ST for better fitting of differential side bearing ST 498427200 FLANGE WRENCH G3M0094 DIFFERENTIALS 2 Screw in side left side holder until light contact is made with ST WRENCH ST 499785500 3 Back off side TE side holder approximate ly 1 1 2 teeth of holder and tighten left side holder by approximately 2 teeth approximately 1 1 2 1 2 teeth Back off amount of side left side holder 1 2 tooth This 1 2 tooth gives preload 4 Temporarily tighten lock plate NOTE Turn over lock plate to displace holder 1 2 tooth G3M0063 5 Measure the crown gear to drive pinion backlash Set magnet base on differential carri er Align contact point of dial gauge with tooth face of crown
12. drive pinion head Example of calculation To 2 20 1 20 3 40 mm N 0 23 mm H 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 Part No Thickness mm in 383495200 3 09 0 1217 383535200 0 1264 383505200 3 12 0 1228 383515200 3 15 0 1240 383525200 3 18 0 1252 383545200 383555200 3 21 0 3 24 0 1276 3 27 0 1287 383565200 3 30 0 1299 383575200 3 33 0 1311 383585200 3 36 0 1323 383595200 3 39 0 1335 383605200 3 42 0 1346 383615200 383625200 3 48 0 1370 383635200 3 51 0 1382 383645200 3 54 0 1394 383655200 3 57 0 1406 383665200 3 60 0 1417 383675200 3 63 0 1429 383685200 3 45 0 1358 3 66 0 1441 4 Install the selected pinion height adjusting shim on drive pinion and press the rear bearing cone into position with ST ST 398177700 INSTALLER eres ST S3M0519A DI 32 REAR DIFFERENTIAL FOR T TYPE 5 Insert drive pinion into differential carrier install the previously selected bearing preload adjusting spacer and washer B3M0560B A Drive pinion B Bearing adjusting spacer C Washer D Differential carrier 6 Press fit front bearing co
13. gear and move crown gear while holding drive pinion still Read value indicated on dial gauge NOTE If measured backlash is not within specified range repeat procedures for pinion crown gear set back lash adjustment and differential side bearing pre load adjustment DI 51 REAR DIFFERENTIAL FOR VA TYPE DIFFERENTIALS Backlash 0 10 0 15 mm 0 0039 0 0059 in 15 Draw a matching mark on both differential car rier and holder Remove holder one side at a time Replace in the original position after inserting an O ring and applying grease to threaded portion A Matching mark B Holder 16 Tighten bolt of lock plate to specified torgue Tightening torgue 25 Nm 2 5 kgf m 18 1 ft lb 17 Re check crown gear to pinion backlash Backlash 0 10 0 15 mm 0 0039 0 0059 in 18 Check the crown gear runout on its back sur face and make sure pinion and crown gear rotate smoothly Limit of runout 0 05 mm 0 0020 in S3M0525 19 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 contact pattern after rotating crown gear several revolutions back and forth until a definite contact pattern appears on the crown gear 2 When the contact pattern is incorrect read just according to the instructions given in TOOTH CONTACT PATTERN NOTE
14. inserted mm N Reading of thickness gauge mm H Figure marked on drive pinion head DI 36 REAR DIFFERENTIAL FOR T TYPE TOOTH CONTACT PATTERN DIFFERENTIALS Condition Correct tooth contact Tooth contact pattern slightly shifted towards toe under no load rotation When loaded contact pattern moves toward heel Face contact Backlash is too large Contact pattern Heel side Wa Ed ER G3M0098A This may cause noise and chipping at tooth ends re ENE De G3M0098B Adjustment Increase thickness of drive pinion height adjusting shim in order to bring drive pin ion closer to crown gear center G3MO0098F Flank contact Backlash is too small This may cause noise and stepped wear on surfaces ER a eee G3M0098C Reduce thickness of drive pinion height adjusting shim in order to move drive pin ion away from crown gear pa G3M0098G Toe contact Contact area is small Heel contact Contact area is small mb Adjusting direction of drive pinion C gt Adjusting direction of crown gear This may cause chipping at toe ends G3M0098D This may cause chipping at heel ends ENG GSMOOSBE DI 37 Adjust as for flank contact G3M0098G Adjust as for face contact G3M0098F REAR DIFFERENTIAL FOR T TYPE DIFFERENTIALS 19 Install rear cover and tighten bolts to specified torque CAUTION Securely connect ground terminal of rear differ ential temperature
15. lock pin holes CAUTION Before installing bolts apply Lock Tite to bolt threads Lock Tite THREE BOND 1324 or equivalent NOTE Tighten diagonally while tapping the bolt heads Tightening torque G 103 N m 10 5 kgf m 76 ft lb S3M0509 13 Press side bearing cone onto differential case EET EA EE o with ST 1 Measure the side gear backlash ST 398487700 DRIFT Side gear back clearance LL 0 10 0 20 mm 0 0039 0 0079 in ST ee Gr KKM G3M0091 14 Adjusting side bearing retainer shims WA Banisa 1 The driven gear backlash and side bearing preload can be determined by the side bearing retainer shim thickness 2 Install the differential case assembly into dif Side gear thrust washer ferential carrier in the reverse order of disas Part No Thickness mm in sembly 383445201 0 75 0 80 0 0295 0 0315 383445202 0 80 0 85 0 0315 0 0335 2 Adjust the backlash as specified by select ing side gear thrust washer 383445204 0 90 0 95 0 0354 0 0374 383445205 0 95 1 00 0 0374 0 0394 383445203 0 85 0 90 0 0335 0 0354 3 Check the condition of rotation after apply ing oil to the gear tooth surfaces and thrust sur faces 3M0533 DI 34 REAR DIFFERENTIAL FOR T TYPE 3 Install side retainer shims and O rings to the left and right retainers from which they we
16. rear crossmember 21 Remove front member from body G3M0058 REAR DIFFERENTIAL FOR VA TYPE DIFFERENTIALS 22 Remove rear differential from body G3M0059 B INSTALLATION To install reverse the removal sequence 1 Position front member on body by passing it un der parking cable and securing to rear differential NOTE When installing rear differential front member do not confuse the installation sequence of the upper and lower stoppers 2 Install DOJ of rear drive shaft into rear differen tial lt Ref to DI 59 REPLACEMENT Rear Differ ential Side Oil Seal gt ST 28099PA090 SIDE OIL SEAL PROTEC TOR Bee G3M1026 3 Install in the reverse order of removal 4 After installation fill differential carrier with gear oil to the upper plug level NOTE Use a new aluminum gasket when installing the plug Oil capacity 0 8 2 0 8 US qt 0 7 Imp qt Tightening torque 34 N m 3 5 kgf m 25 3 ft lb algi S3M0527A A Filler plug B Drain plug C DISASSEMBLY To detect real cause of trouble inspect the follow ing items before disassembling e Tooth contact of crown gear and pinion and backlash s Runout of crown gear at its back surface e Turning resistance of drive pinion 1 Set ST on vise and install the differential assem bly to ST ST 398217700 ATTACHMENT ST 2g _ G3M0060 2 Drain gear oil by remov
17. sensor Tightening torque 29 N m 3 0 kgf m 21 7 ft lb G3M1050 E INSPECTION Wash all the disassembled parts clean and exam ine them for wear damage or other defects Re pair or replace defective parts as necessary 1 Crown gear and drive pinion s If abnormal tooth contact is evident find out the cause and adjust to give correct tooth contact at as sembly Replace the gear if excessively worn or in capable of adjustment s If crack score or seizure is evident replace as a set Slight damage of tooth can be corrected by oil stone or the like 2 Side gear and pinion mate gear e Replace if crack score or other defects are evi dent on tooth surface e Replace if thrust washer contacting surface is worn or seized Slight damage of the surface can be corrected by oil stone or the like 3 Bearing Replace if seizure peeling wear rust dragging during rotation abnormal noise or other defect is evident 4 Thrust washers of side gear and pinion mate gear Replace if seizure flaw abnormal wear or other defect is evident 5 Oil seal Replace if deformed or damaged and at every dis assembling 6 Differential carrier Replace if the bearing bores are worn or damaged 7 Differential case Replace if its sliding surfaces are worn or cracked 8 Companion flange Replace if the oil seal lip contacting surfaces have flaws 1 SIDE GEAR BACKLASH Using a dial gauge check the backlash of
18. 1429 in 383685200 3 66 mm 0 1441 in Side gear backlash 0 1 0 2 mm 0 0039 0 0079 in Part No Thickness 383445201 0 75 0 80 mm 0 0295 0 0315 in Side gear thrust washer 383445202 0 80 0 85 mm 0 0315 0 0335 in Non Turbo model 383445203 0 85 0 90 mm 0 0335 0 0354 in 383445204 0 90 0 95 mm 0 0354 0 0374 in 383445205 0 95 1 0 mm 0 0374 0 0394 in Side bearing standard width 20 00 mm 0 7874 in Part No Thickness 383475201 0 20 mm 0 0079 in 383475202 0 25 mm 0 0098 in 383475203 0 30 mm 0 0118 in 383475204 0 40 mm 0 0157 in 383475205 0 50 mm 0 0197 in Crown gear to drive pinion backlash Limit 0 10 0 20 mm 0 0039 0 0079 in Crown gear runout on its back sunface 0 05 mm 0 0020 in Side bearing retainer shim DI 5 GENERAL DESCRIPTION DIFFERENTIALS B COMPONENT 1 REAR DIFFERENTIAL FOR T TYPE WITHOUT LSD Kid B3M0130C 1 Pinion crown gear set 13 Side bearing 25 Air breather cap 2 Pinion height adjusting washer 14 O ring 26 Stud bolt 3 Rear bearing 15 Side bearing retainer shim 27 Oil filler plug 4 Bearing preload adjusting spacer 16 Side bearing retainer 28 Oil drain plug 5 Bearing preload adjusting washer 17 Sid
19. 2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair oF SUBARU vehicles DRIVE SHAFT SYSTEM This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of ABS components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual ABS DIAGNOSTICS fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition BRAKE When replacement of parts during repair work is needed be sure to use SUBARU genuine parts PARKING BRAKE TRANSFER CASE POWER ASSISTED SYSTEM POWER STEERING All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD G1830GE5 ee MAAR eee Et DIFFERENTIALS 1 General Description is eee eee ER ER SE eee 2 Differential Gear eT 3 Front Differential sees ee ee ee ee ee ee ee ee ee ee ee RR ee RR ee ee ee 4 Rear Differential for T type ss Ee De ee se Re Ee De De Wee RE ED ee 5 Rear Differential for VA type 6 Rear Differential Front Oil Seal sese 57 7 Rear
20. 2295AA240 0 250 0 0098 4 Install the selected pinion height adjusting shim on drive pinion and press the rear bearing cone into position with ST ST 498175500 INSTALLER eo ST S3M0519A DI 48 REAR DIFFERENTIAL FOR VA TYPE 5 Insert drive pinion into differential carrier install the previously selected bearing preload adjusting spacer and washer H3M1666A Drive pinion Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier 6 Press fit front bearing cone into carrier with ST1 ST2 and ST3 ST1 32285AA000 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER Z G3M0085 7 Insert spacer then press fit pilot bearing with ST1 and ST2 ST1 399780104 WEIGHT ST2 899580100 INSTALLER ST1 S3M0520A DIFFERENTIALS 8 Fit a new oil seal with ST NOTE e Press fit until end of oil seal is 1 mm 0 04 in in ward from end of carrier s Apply grease between the oil seal lips ST 498447120 DRIFT S t I FR Id LE G3M0087 9 Press fit companion al with ST1 and ST2 CAUTION Be careful not to damage bearing ST1 899874100 INSTALLER ST2 399780104 WEIGHT S3M0521A 10 Install self locking nut Then tighten it with ST ST 498427200 FLANGE WRENCH Tightening torque 188 N m 19 2 kgf m 139 ft lb DI 49 REAR DIFFERENTIAL
21. 7874 0 10 0 20 0 0039 0 0079 0 10 0 15 0 0039 0 0059 Crown gear runout on its back surface mm in Less than 0 05 0 0020 2 ADJUSTING PARTS s VA type Front and rear bearing preload at companion New bearing flange bolt hole N kgf Ib Side gear backlash mm in Crown gear to drive pinion backlash mm in Front and rear bearing preload at com KEES 12 7 32 4 N panion flange bolt hole g 1 3 3 3 kgf 2 9 7 3 Ib Part No Length 32288AA040 52 3 mm 2 059 in 32288AA050 52 5 mm 2 067 in 31454AA100 52 6 mm 2 071 in 32288AA060 52 7 mm 2 075 in 31454AA110 52 8 mm 2 079 in Preload adjusting spacer 32288AA070 52 9 mm 2 083 in 31454AA120 53 0 mm 2 087 in 32288AA080 53 1 mm 2 091 in 32288AA090 53 3 mm 2 098 in Part No Thickness 38336AA000 1 500 mm 0 0591 in 38336AA120 1 513 mm 0 0596 in 38336AA010 1 525 mm 0 0600 in 38336AA130 1 538 mm 0 0606 in 38336AA020 1 550 mm 0 0610 in 38336AA140 1 563 mm 0 0615 in 38336AA030 1 575 mm 0 0620 in 38336AA150 1 588 mm 0 0625 in 38336AA160 1 613 mm 0 0635 in 38336AA050 1 625 mm 0 0640 in 38336AA170 1 638 mm 0 0645 in Preload adjusting washer 38336AA060 1 650 mm 0 0650 in 38336AA070 1 675 mm 38336AA190 1 688 mm 0 0665 in 38336AA0
22. 80 1 700 mm 0 0669 in 38336AA200 1 713 mm 0 0674 in 38336AA210 1 738 mm 0 0684 in 38336AA100 1 750 mm 0 0689 in 38336AA220 1 763 mm 0 0694 in 38336AA1 10 1 775 mm 0 0699 in 0 0659 in DI 3 DIFFERENTIALS Pinion height adjusting shim GENERAL DESCRIPTION Part No Thickness 32295AA200 0 150 mm 0 0059 in 32295AA210 0 175 mm 0 0069 in 32295AA220 32295AA230 0 200 mm 0 0079 in 32295AA240 0 250 mm 0 0098 in 32295AA250 0 225 mm 0 0089 in 0 275 mm 0 0108 in Side gear thrust washer 0 05 0 15 mm 0 0020 0 0059 in Side gear thrust washer 80313501 1 0 925 0 950 mm 0 0364 0 0374 in 803135012 0 950 0 975 mm 0 0374 0 0384 in 803135013 0 975 1 000 mm 0 0384 0 0394 in 803135014 803135015 1 000 1 025 mm 0 0394 0 0404 in 1 025 1 050 mm 0 0404 0 0413 in Crown gear to drive pinion backlash Crown gear runout on its back sunface T type Front and rear bearing preload at com panion flange bolt hole Limit 0 10 0 15 mm 0 0039 0 0059 in New bearing 0 05 mm 0 0020 in 19 6 28 4 N 2 0 2 9 kgf 4 4 6 4 ID Used bearing 8 34 16 67 N 0 85 1 7 kgf 1 87 3 75 Ib Preload adjusting spacer Preload adjusting washer Part No Length 383695201 383695202 56
23. BLY Rear Differential for T type gt 3 TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION Adjust the tooth contact between crown gear and drive pinion gear lt Ref to DI 30 ASSEMBLY Rear Differential for T type gt 4 TOTAL PRELOAD Adjust side bearing shim lt Ref to DI 30 ASSEMBLY Rear Differential for T type gt DI 39 REAR DIFFERENTIAL FOR VA TYPE DIFFERENTIALS 5 Rear Differential for VA type A REMOVAL 1 Set the vehicle on the lift 2 Disconnect ground terminal from battery Move select lever or gear shift lever to N Release the parking brake Loosen wheel nuts Jack up vehicle and support it with sturdy racks Remove wheels 8 Remove rear exhaust pipe and muffler Non turbo model without OBD lt Ref to EX SOHCw oOBD 13 REMOVAL Rear Exhaust Pipe and lt Ref to EX SOHCw oOBD 14 REMOVAL Muffler gt Non turbo model with OBD lt Ref to EX SOHC 11 REMOVAL Rear Exhaust Pipe and lt Ref to EX SOHC 12 REMOVAL Muffler gt Turbo model lt Ref to EX DOHC TURBO 13 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX DOHC TURBO 14 REMOVAL Muffler gt 9 Remove front cover of rear differential mount EE EE EE 3 4 5 6 7 10 Remove propeller shaft CAUTION When removing propeller shaft pay attention not to damage the sliding surfaces of rear drive shaft extension spline oil seal and sleeve yoke NOTE
24. CTION 1 Check rear differential member for damage bend or corrosion If damage bend or corrosion is excessive replace rear differential member 2 Check bushings of rear differential member for cracking hardening or damage If cracking hardening or damage is excessive re place rear differential member DI 64 GENERAL DIAGNOSTIC TABLE DIFFERENTIALS 9 General Diagnostic Table A INSPECTION Symptom or trouble 1 Oil leakage Possible cause 1 Worn scratched or incorrectly seated front or side oil seal Scored battered or excessively worn sliding surface of com panion flange 2 Clogged or damaged air breather Remedy Repair or replace Clean repair or replace 3 Loose bolts on differential spindle or side retainer or incorrectly fitted O ring Tighten bolts to specified torque Replace O ring 4 Loose rear cover attaching bolts or damaged gasket Tighten bolts to specified torque Replace gasket and apply liquid packing 5 Loose oil filler or drain plug 6 Wear damage or incorrectly fitting for spindle side retainer and oil seal Retighten and apply liquid packing Repair or replace 2 Seizure NOTE Seized or damaged parts should be re placed and also other parts should be thoroughly checked for any defect and should be repaired or replaced as re quired 1 Insufficient backlash for hypoid gear 2 Excessive preload for side rear or fro
25. Differential Side Oil Seal 59 8 Rear Differential Member eee ee ee ee ee ee ee ee ee ee Re EE ee 64 9 General Diagnostic Table EE REKE GREG RES SE KEER eek Re ER ed Ga eek ge 65 GENERAL DESCRIPTION DIFFERENTIALS 1 General Description A SPECIFICATIONS Non Turbo T type Rear differential type EF with LSD Type of gear Hypoid gear ae I OL gear 4 111 37 9 3 900 39 10 3 545 39 11 Oil capacity 0 80 0 8 US at 0 7 Imp at Rear differential gear oil GL 5 e Identification s Rear differential gear oil When replacing a rear differential assembly select Recommended oil the correct one according to the following table CAUTION CAUTION Each oil manufacturer has its base oil and addi Using the different rear differential assembly tives Thus do not mix two or more brands causes the drive line and tires to drag or emit TEM abnormal noise when AWD is selected Rear differential gear oil API Classification SAE Viscosity No and Application Temperature CC 30 26 15 5 0 15 2530 F 22 15 5 23 32 59 77 86 H3M1272A DR0001 DI 2 GENERAL DESCRIPTION DIFFERENTIALS 1 SERVICE DATA 19 6 28 4 2 0 2 9 4 4 6 4 12 7 32 4 1 3 3 3 2 9 7 3 Used bearing 8 34 16 67 0 85 1 7 1 87 3 75 0 10 0 20 0 0039 0 0079 0 05 0 15 0 0020 0 0059 Side bearing standard width mm in 20 00 0
26. Extract the companion flange with a puller S3M0511 14 Press the end of drive pinion shaft and extract it together with rear bearing cone preload adjusting spacer and washer NOTE Hold the drive pinion so as not to drop it DRIFT ST 398467700 G3M0074 15 Remove rear bearing cone from drive pinion by supporting cone with ST NOTE Place the replacer so that its center recessed side faces the pinion gear ST 398517700 REPLACER S3M0512A DI 29 REAR DIFFERENTIAL FOR T TYPE DIFFERENTIALS 16 Remove front oil seal from differential carrier using ST ST 398527700 S3MO513 17 Remove pilot bearing together with front bear ing cone using ST ST 398467700 PULLER ASSY DRIFT S3M0514A A Pinion bearing B Front bearing C Rear bearing cup 18 When replacing bearings tap front bearing cup and rear bearing cup in this order out of case by us ing a brass bar oe ra wv S3M0515A A 2 cutouts along diagonal lines B Tap alternately with brass bar D ASSEMBLY 1 Precautions for assembling e Assemble in the reverse order of disassembling e Check and adjust each part during assembly e Keep the shims and washers in order so that they are not misinstalled e Thoroughly clean the surfaces on which the shims washers and bearings are to be installed e Apply g
27. FOR VA TYPE DIFFERENTIALS 11 Assembling differential case Install side gears and pinion mate gears with their thrust washers and pinion mate shaft into differen tial case NOTE gt Apply gear oil on both sides of the washer and on the side gear shaft before installing e Insert the pinion mate shaft into the differential case by aligning the lock pin holes G3M0089 1 Measure the side gear backlash Side gear back clearance 0 05 0 15 mm 0 0020 0 0059 in B3M1933 2 Adjust the side gear backlash as specified by selecting side gear thrust washer Side gear thrust washer Part No 803135011 Thickness mm in 0 925 0 950 0 0364 0 0374 803135012 0 950 0 975 0 0374 0 0384 803135013 803135014 1 000 1 025 0 0394 0 0404 803135015 1 025 1 050 0 0404 0 0413 0 975 1 000 0 0384 0 0394 3 Check the condition of rotation after apply ing oil to the gear tooth surfaces and thrust sur faces 4 After driving in pinion shaft lock pin stake the both sides of the hole to prevent pin from fall ing off 5 Install crown gear on differential case CAUTION Before installing bolts apply Lock Tite to bolt threads Lock Tite THREE BOND 1324 or equivalent NOTE Tighten diagonally while tapping the bolt heads Tightening torque 62 N m 6 3 kgf m 45 6 ft lb
28. RIFT 2 Press front bearing race into differential car rier with ST1 and ST2 ST1 398477701 HANDLE ST2 498447110 DRIFT G3M0080 3 Insert front bearing cone CAUTION Use a new front bearing cone 4 Insert ST1 into case with pinion height ad justing shim and rear bearing cone fitted onto it CAUTION s Re use the used washer if not deformed s Use a new rear bearing cone 5 Then install preload adjusting spacer and washer front bearing cone ST2 companion flange and washer and self locking nut ST1 498447150 DUMMY SHAFT ST2 32285AA000 DUMMY COLLAR ST sT1 S3M0516A A Pinion height adjujusting shim B Preload adjusting spacer C Preload adjusting washer 6 Turn ST1 with hand to make it seated and tighten drive pinion nut while measuring the pre load with spring balance Select preload adjust ing washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque CAUTION Use a new self locking nut NOTE s Be careful not to give excessive preload e When tightening the drive pinion nut lock ST1 with ST2 as shown in the figure ST1 398507704 BLOCK ST2 498447150 DUMMY SHAFT Tightening torque 188 N m 19 2 kgf m 139 ft lb G3M1038 DI 46 REAR DIFFERENTIAL FOR VA TYPE Front and rear bearing preload For new bearing 12 7 32 4 N 1 3 3 3 kgf 2 9 7 3 Ib at
29. ad For used bearing For new bearing 3 8 34 16 67 N 0 85 1 7 kgf 1 87 3 75 Ib 19 6 28 4 N 2 0 2 9 kgf 4 4 6 4 Ib at companion flange bolt hole at companion flange bolt hole For used bearing Adjusting preload for front and rear bearings 8 34 16 67 N 0 85 1 7 kgf 1 87 3 75 Ib at companion flange bolt hole DI 31 REAR DIFFERENTIAL FOR T TYPE DIFFERENTIALS NOTE At this time install a pinion height adjusting shim which is temporarily selected or the same as that used before Measure and record the thickness ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE ST3 398507703 DUMMY COLLAR S3M0518B A Pinion height adjusting shim 2 Measure the clearance N between the end of ST2 and the end surface of ST1 by using a thickness gauge NOTE Make sure there is no clearance between the case and ST2 ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE H3M1309B 3 Obtain the thickness of pinion height adjust ing shim to be inserted from the following formu la and replace the temporarily installed shim with this one T To N H x 0 01 0 20 mm 0 0079 in NOTE Use copies of this page Thickness of shim temporarily inserted mm in Thickness of pinion height adjusting shim mm in Reading of thickness gauge mm in Figure marked on
30. ce as a set Slight damage of tooth can be corrected by oil stone or the like 2 Side gear and pinion mate gear e Replace if crack score or other defects are evi dent on tooth surface e Replace if thrust washer contacting surface is worn or seized Slight damage of the surface can be corrected by oil stone or the like 3 Bearing Replace if seizure peeling wear rust dragging during rotation abnormal noise or other defect is evident 4 Thrust washers of side gear and pinion mate gear Replace if seizure flaw abnormal wear or other defect is evident 5 Oil seal Replace if deformed or damaged and at every dis assembling 6 Differential carrier Replace if the bearing bores are worn or damaged 7 Differential case Replace if its sliding surfaces are worn or cracked 8 Companion flange Replace if the oil seal lip contacting surfaces have flaws DIFFERENTIALS 1 SIDE GEAR BACKLASH Using a dial gauge check the backlash of the side gear Side gear backlash 0 05 0 15 mm 0 0020 0 0059 in If side gear backlash is not within the specification adjust clearance as specified by selecting side gear thrust washer B3M1934 2 CROWN GEAR BACKLASH Using a dial gauge check the backlash of the crown gear Crown gear backlash 0 10 0 15 mm 0 0039 0 0059 in If crown gear backlash is not within the specifica tion adjust the side bearing preload or repair if nec essary
31. companion flange bolt hole S3M0517 DIFFERENTIALS DI 47 Part No Thickness mm in 38336AA000 1 500 0 0591 38336AA120 1 513 0 0596 38336AA010 1 525 0 0600 38336AA130 1 538 0 0606 38336AA020 1 550 0 0610 38336AA1 40 1 563 0 0615 38336AA030 1 575 0 0620 38336AA150 1 588 0 0625 38336AA040 1 600 0 0630 38336AA160 1 613 0 0635 Preload adjusting 38336AA050 1 625 0 0640 washer 38336AA170 1 638 0 0645 38336AA060 1 650 0 0650 38336AA180 1 663 0 0655 38336AA070 1 675 0 0659 38336AA190 1 688 0 0665 38336AA080 1 700 0 0669 38336AA200 1 713 0 0674 38336AA090 1 725 0 0679 38336AA210 1 738 0 0684 38336AA100 1 750 0 0689 38336AA220 1 763 0 0694 38336AA110 1 775 0 0699 Part No Length mm in 32288AA040 52 3 2 059 32288AA050 52 5 2 067 31454AA100 52 6 2 071 Preload adjusting 32288AA060 52 7 2 075 spacer 31454AA110 52 8 2 079 32288AA070 52 9 2 083 31454AA120 53 0 2 087 32288AA080 53 1 2 091 32288AA090 53 3 2 098 REAR DIFFERENTIAL FOR VA TYPE DIFFERENTIALS 3 Adjusting drive pinion height Adjust drive pinion height with shim installed be tween 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 Front and rear bearing preload For new bearing 12 7 32 4 N 1 3 3
32. e oil seal 29 Rear cover 6 Differential carrier 18 Side gear thrust washer 30 Differential case 7 Front bearing 19 Side gear Tightening torque N m kgf m ft lb 8 Spacer 20 Pinion mate gear T1 10 3 1 05 7 6 9 Pilot bearing 21 Pinion mate gear washer T2 29 4 3 00 21 7 10 Front oil seal 22 Pinion shaft lock pin T3 49 0 5 0 36 2 11 Companion flange 23 Circlip T4 103 0 10 50 75 9 12 Self locking nut 24 Pinion mate shaft T5 181 4 18 50 133 8 DI 6 GENERAL DESCRIPTION DIFFERENTIALS 2 REAR DIFFERENTIAL FOR T TYPE WITH LSD 1 d at 2 3 4 L 5 ae pg B3M1662A 1 Pinion crown gear set 12 Self locking nut 23 Oil filler plug 2 Pinion height adjusting shim 13 Side bearing 24 Oil drain plug 3 Rear bearing 14 O ring 4 Bearing preload adjusting spacer 15 Side bearing retainer shim Tightening torque N m kgf m ft lb 5 Bearing preload adjusting washer 16 Side bearing retainer T1 10 3 1 05 7 6 6 Differential carrier 17 Side oil seal T2 29 4 3 00 21 7 7 Front bearing 18 Gasket T3 49 0 5 00 36 2 8 Collar 19 Differential case T4 103 0 10 50 75 9 9 Pilot bearing 20 Rear cover T5 181 4 18 50 133 8 10 Front oil seal 21 Air breather cap 11 Companion flange 22 Stud bolt DI 7 GENERAL DESCRIPTION DIFFERENTIALS 3 REAR DIFFERENTIAL FOR VA TYPE
33. e the axle shaft holder DI 61 REAR DIFFERENTIAL SIDE OIL SEAL DIFFERENTIALS NOTE ST 498447100 OIL SEAL INSTALLER The side spline shaft circlip comes out together with the shaft G3M0048 12 Insert the DOJ into rear differential CAUTION Before inserting replace the circlip at the end of the spline shaft with a new one Axle shaft holder T 1 Install ST to rear differential NI ST 28099PA090 SIDE OIL SEAL PROTEC S TOR H3M1664A 9 Secure rear drive shaft to rear crossmember us ing wire G3M0256 2 Install the spline shaft until the spline portion is inside the side oil seal G3M0049 3 Remove ST ST 28099PA090 SIDE OIL SEAL PROTEC TOR 4 Completely insert DOJ into rear differential by pressing rear housing G3M0047 11 Drive in a new side oil seal with ST CAUTION Apply chassis grease between the oil seal lips DI 62 REAR DIFFERENTIAL SIDE OIL SEAL DIFFERENTIALS NOTE Make sure that oil seal lip is not folded over inward H4M1095 13 Hereafter re assemble in reverse order of dis assembly DI 63 REAR DIFFERENTIAL MEMBER DIFFERENTIALS 8 Rear Differential Member A REMOVAL 1 Set the vehicle on the lift 2 Disconnect ground terminal from battery Move selector lever or gear shift lever to N Release the parking brake Loosen wheel nuts Jack up vehicle and support it w
34. ear oil when installing the bearings and thrust washers e Be careful not to mix up the right and left hand races of the bearings e Replace the oil seal with new one at every disas sembly Apply chassis grease between the lips when installing the oil seal G3M0079 2 Adjusting preload for front and rear bearings Adjust the bearing preload with spacer and washer between front and rear bearings Pinion height ad justing washer are not affected by this adjustment The adjustment must be carried out without oil seal inserted 1 Press rear bearing race into differential car rier with ST1 and ST2 ST1 398477701 HANDLE ST2 398477703 DRIFT 2 G3M1037 2 Insert Es into carrier with pinion height ad justing washer and rear bearing cone fitted onto it CAUTION s Re use the used washer if not deformed Use a new rear bearing cone DI 30 REAR DIFFERENTIAL FOR T TYPE DIFFERENTIALS 3 Then install preload adjusting spacer and washer front bearing cone ST2 companion flange and washer and drive pinion nut ST1 398507702 DUMMY SHAFT ST2 398507703 DUMMY COLLAR S3M0518A Part No Thickness mm in 383705200 2 59 0 1020 S3M0516A 383715200 2 57 0 1012 383725200 2 55 0 1004 A Pinion height adjusting shim 383735200 2 53 0 0996 B Preload adjusting space
35. from battery Move select lever or gear shift lever to N Release the parking brake Loosen both wheel nuts 5 Jack up the vehicle and support it with rigid racks 6 Remove wheels 7 Remove rear exhaust pipe and muffler Non turbo model without OBD lt Ref to EX SOHCw oOBD 13 REMOVAL Rear Exhaust Pipe and lt Ref to EX SOHCw oOBD 14 REMOVAL Muffler gt Non turbo model with OBD lt Ref to EX SOHC 11 REMOVAL Rear Exhaust Pipe and lt Ref to EX SOHC 12 REMOVAL Muffler gt Turbo model lt Ref to EX DOHC TURBO 13 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX DOHC TURBO 14 REMOVAL Muffler gt 8 Remove the DOJ of rear drive shaft from rear dif ferential 1 Remove the ABS sensor cable clamp and parking brake cable clamp from bracket oa ABS sensor cable clamp 0 L LY 1 Parking brake 7 cable clamp 2 3 4 EE EF H3M1397A 2 Remove the ABS sensor cable clamp from the trailing link ABS sensor cable clamp H3M1398A DI 59 DIFFERENTI 3 Remove the ABS sensor cable clamp parking brake cable guide from the trailing li ALS and nk Parking brake cable guide ABS sensor cable LL clamp H3M1399A 4 Remove the rear stabilizer link Stabilizer link H3M1396A 5 Remove the bolts which secure the tra link to the housing iling G3M0042 6 Remove the bolts which secure the front
36. hims Turning resistance increase 2 9 10 8 N 0 3 1 1 kgf 0 7 2 4 Ib 15 Re check crown gear to pinion backlash Backlash 0 10 0 20 mm 0 0039 0 0079 in G3M1047 DI 35 REAR DIFFERENTIAL FOR T TYPE DIFFERENTIALS 16 Check the crown gear runout on its back sur 2 Hypoid gear backlash ae make sure pinion and crown gear rotate Backlash T 0 10 0 20 mm 0 0039 0 0079 in Limit of runout Less than 0 05 mm 0 0020 in G3M1047 S3M0525 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 contact pattern after rotating crown gear several revolutions back and forth until a definite contact pattern appears on the crown gear 2 When the contact pattern is incorrect read just according to the instructions given in TOOTH CONTACT PATTERN NOTE Be sure to wipe off red lead completely after adjust ment is completed 18 If proper tooth contact is not obtained once again adjust the drive pinion height changing RH and LH side bearing retainer shims and the hypoid gear backlash 1 Drive pinion height ST1 398507702 DUMMY SHAFT ST2 398507701 DIFFERENTIAL CARRIER GAUGE Nee H3M1309B T To N Hx 0 01 0 20 mm Where T Thickness of pinion height adjusting shim mm To Thickness of shim temporarily
37. id packing to plug Fluid packing THREE BOND 1105 or equivalent Oil capacity 0 8 2 0 8 US qt 0 7 Imp qt Tightening torque 49 N m 5 0 kgf m 36 2 ft Ib DIFFERENTIALS S3M0527A A Filler plug B Drain plug C DISASSEMBLY To detect real cause of trouble inspect the follow ing items before disassembling e Tooth contact of crown gear and pinion and backlash s Runout of crown gear at its back surface e Turning resistance of drive pinion 1 Set ST on vise and install the differential assem bly to ST ST 398217700 ATTACHMENT 2 Drain gear oil by removing plug 3 Remove the air breather cap NOTE Do not attempt to replace the air breather cap un less necessary S3M0530A A Air breather cap B Rear cover DI 27 REAR DIFFERENTIAL FOR T TYPE DIFFERENTIALS 4 Remove rear cover by loosening retaining bolts S3M0531A A Rear cover B Differential carrier 5 Make right and left side bearing retainers in or der to identify them at reassembly Remove side bearing retainer attaching bolts set ST to differen tial case and extract right and left side bearing re tainers with a puller CAUTION Each shim which is installed to adjust the side bearing preload should be kept together with its mating retainer ST 398457700 ATTACHMENT S3M0532A 6 Pull out differential case assembly from differen tial carr
38. ier CAUTION Be careful not to hit the teeth against the case S3M0533 7 When replacing side bearing pull bearing cup from side bearing retainer using ST ST 398527700 PULLER ASSY S3M0534A 8 Extract bearing cone with ST CAUTION Do not attempt to disassemble the parts unless necessary NOTE e Set puller so that its claws catch the edge of the bearing cone s Never mix up the right and left hand bearing rac es and cones ST 398527700 PULLER SET G3Mo068 9 Remove crown gear by loosening crown gear bolts CAUTION Further disassembling is not allowed S3M0509 DI 28 REAR DIFFERENTIAL FOR T TYPE 10 Drive out pinion shaft lock pin from crown gear side Without LSD NOTE The lock pin is staked at the pin hole end on the dif ferential carrier do not drive it out forcibly before unstaking it ST 899904100 STRAIGHT PINREMOVER 11 Draw out pinion mate shaft and remove pinion mate gears side gears and thrust washers With out LSD NOTE The gears as well as thrust washers should be marked or kept separated left and right and front and rear C C S3M0510A A Side gear B Pinion mate gear C Thrust washer D Differential case E Pinion mate shaft 12 Hold companion flange with ST and remove drive pinion nut ST 498427200 FLANGE WRENCH G3M1052 DIFFERENTIALS 13
39. ing pinion height CARRIER GAUGE e For VA type B3M1925 498447110 DRIFT e Used for press fitting the bearing race front of differential carrier e For VA type B3M1926 498447150 DUMMY SHAFT e Used for adjusting pinion height and Pre load e For VA type B3M1927 DI 19 DIFFERENTIALS GENERAL DESCRIPTION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498515500 REPLACER e Used for removing rear bearing cone e For VA type B3M1911 32285AA000 DUMMY COLLAR e Used for adjusting pinion height and Pre load e For VA type B3M1977 499705404 SEAT e Used for removing side bearing race e Used with PULLEY ASSY 499705401 e For VA type B3M1928 499705401 PULLEY ASSY e Used for removing side bearing race B3M1930 DI 20 e Used with SEAT 499705404 e For VA type GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899874100 INSTALLER e Used for installing companion flange LTE 7 8 L E 4 H Q B3M1931 899524100 PULLER SET e Used for removing side bearing cone of dif fer B3M1932A DI 21 ential e For VA type 1 Puller 2 Cap GENERAL DESCRIPTION DIFFERENTIALS 2 GENERAL PURPOSE TOOLS TOOL NAME REMARKS Transmission jack Used for assembly disassembly of rear differential Puller Used for removal of side bearing retainer T type Thickness gauge Used for measuring clearance Tire lever Used for removal
40. ing plug 3 Remove rear cover by loosening retaining bolts S3M0506 DI 42 REAR DIFFERENTIAL FOR VA TYPE 4 Replace air breather cap NOTE Do not attempt to replace the air breather cap un less necessary A A Air breather cap B Rear cover B S3M0507A 5 Remove right and left lock plates d G3M0063 6 Remove right and left holders with ST ST 499785500 WRENCH G3M0064 DIFFERENTIALS 7 Pull out differential assembly from differential case CAUTION Be careful not to hit the teeth against the case G3M0065 8 Remove bearing race from right and left holders with ST1 and ST2 ST1 499705401 PULLEY ASSY ST2 499705404 SEAT A Bearing race B Holder 9 Remove oil seal from right and left holders with screwdriver CAUTION Perform this operation only when changing oil seal O B3M0132 DI 43 REAR DIFFERENTIAL FOR VA TYPE DIFFERENTIALS 10 Extract bearing cone with ST1 and ST2 CAUTION Do not attempt to disassemble the parts unless necessary NOTE e Set Puller so that its claws catch the edge of the bearing cone e Never mix up the right and left hand bearing rac es and cones ST1 899524100 PULLER SET ST2 399520105 SEAT 11 Remove crown gear by loosening crown gear bolts S3M0509 12 Drive out pinion shaft lock pin from crow
41. ith study racks Remove wheels 8 Remove rear exhaust pipe and muffler Non turbo model without OBD lt Ref to EX SOHCw oOBD 13 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX SOHCw oOBD 14 REMOVAL Muffler gt Non turbo model with OBD lt Ref to EX SOHC 11 REMOVAL Rear Exhaust Pipe and lt Ref to EX SOHC 12 REMOVAL Muffler gt Turbo model lt Ref to EX DOHC TURBO 13 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX DOHC TURBO 14 REMOVAL Muffler gt 9 Remove rear differential front member NOTE When removing rear differential front member work the removal procedure as rear differential T type lt Ref to DI 25 REMOVAL Rear Differential for T type gt VA type lt Ref to DI 40 REMOVAL Rear Differential for VA type gt 10 Remove differential rear member EE EE NN 3 4 5 6 7 B INSTALLATION To install reverse the removal sequence 1 Position front member on body by passing it un der parking brake cable and securing to rear differ ential NOTE When installing rear differential front member do not confuse the installation seqence of the stopper G3M1029 2 Insert DOJ of rear drive shaft into rear differen tial lt Ref to DI 59 REPLACEMENT Rear Differ ential Side Oil Seal gt CAUTION Before inserting replace the differential side oil seal with a new one ST 28099PA090 SIDE OIL SEAL PROTEX TOR order of removal C INSPE
42. ized or damaged side bearing DI 65 Replace GENERAL DIAGNOSTIC TABLE DIFFERENTIALS Symptom or trouble Possible cause Remedy 6 Gear noises NOTE Since noises from engine muffler trans mission 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 coast ing 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 try ing to pick up only differential noise 1 Improper tooth contact of hypoid gear Readjust or replace hypoid gear set Readjust 2 Improper backlash for hypoid gear 3 Scored or chipped teeth of hypoid gear Replace hypoid gear set Replace hypoid gear set 4 Seized hypoid gear 5 Improper preload for front or rear bearings Readjust 6 Seized scored or chipped front or rear bearing Replace 7 Seized scored or chipped side bear ing Replace 8 Vibrating differential carrier DI 66 Replace
43. move pilot bearing together with front bear ing cone using ST ST 398467700 DRIFT S3M0514A A Pilot bearing B Front bearing C Rear bearing cup 20 When replacing bearings tap front bearing cup and rear bearing cup in this order out of case by us ing a brass bar h nas SS S ao N os B S3M0515A A 2 cutouts along diagonal lines B Tap alternately with brass bar DI 45 REAR DIFFERENTIAL FOR VA TYPE DIFFERENTIALS D ASSEMBLY 1 Precautions for assembling e Assemble in the reverse order of disassembling e Check and adjust each part during assembly e Keep the shims and washers in order so that they are not misinstalled e Thoroughly clean the surfaces on which the shims washers and bearings are to be installed gt Apply gear oil when installing the bearings and thrust washers e Be careful not to mix up the right and left hand races of the bearings e Replace the oil seal with new one at every disas sembly Apply chassis grease between the lips when installing the oil seal G3M0079 2 Adjust preload for front and rear bearings Adjust the bearing preload with spacer and washer between front and rear bearings Pinion height ad justing washer are not affected by this adjustment The adjustment must be carried out without oil seal inserted 1 Press rear bearing race into differential car rier with ST1 and ST2 ST1 398477701 HANDLE ST2 398477702 D
44. n gear side NOTE The lock pin is staked at the pin hole end on the dif ferential case do not drive it out forcibly before unstaking it ST 899904100 STRAIGHT PINREMOVER B3M0133 13 Draw out pinion mate shaft and remove pinion mate gears side gears and thrust washers NOTE The gears as well as thrust washers should be marked or kept separated left and right and front and rear S3M0510A A Side gear B Pinion mate gear C Thrust washer D Differential case E Pinion mate shaft 14 Hold companion flange with ST and remove self locking nut ST 498427200 FLANGE WRENCH K AT 7 G3M0072 15 Extract the companion flange with a puller IS3M0511A A Companion B Puller DI 44 REAR DIFFERENTIAL FOR VA TYPE 16 Press the end of drive pinion shaft and extract it together with rear bearing cone preload adjusting spacer and washer NOTE Hold the drive pinion so as not to drop it ST 398467700 DRIFT G3M0074 17 Remove rear bearing cone from drive pinion by supporting cone with ST NOTE Place the replacer so that its center recessed side faces the pinion gear ST 498515500 REPLACER S3M0512A 18 Remove front oil seal from differential carrier using ST ST 398527700 PULLER SET S3M0513A A Differential carrier B Front oil seal DIFFERENTIALS 19 Re
45. ne into case with ST1 ST2 and ST3 ST1 398507703 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER BZ G3M0085 7 Insert spacer then press fit pilot bearing with ST1 and ST2 ST1 399780104 WEIGHT ST2 899580100 INSTALLER ST1 S3M0520A DIFFERENTIALS 8 Fit a new oil seal with ST NOTE e Press fit until end of oil seal is 1 mm 0 04 in in ward from end of carrier s Apply grease between the oil seal lips ST 498447120 DRIFT d E N gt G3M0087 E 9 Press fit companion flange with ST1 and S12 CAUTION Be careful not to damage bearing ST1 899874100 INSTALLER A 7 a S3M0521A 10 Install self locking nut Then tighten it with ST ST 498427200 FLANGE WRENCH Tightening torque 181 N m 18 5 kgf m 134 ft lb G3M1052 11 Assembling differential case Install side gears and pinion mate gears with their thrust washers and pinion mate shaft into differen tial case Without LSD DI 33 REAR DIFFERENTIAL FOR T TYPE DIFFERENTIALS CAUTION 4 After inserting pinion shaft lock pin into dif Apply gear oil on both sides of the washer ferential case stake the both sides of the hole to and on the side gear shaft before installing prevent pin from falling off Insert the pinion mate shaft into the differen 12 Install crown gear on differential case tial case by aligning the
46. ng nuts connecting rear dif ferential to rear crossmember 18 Remove bolts which secure rear differential front member to body Loosen bolt A first then remove bolts B NOTE Support front member with the use of a helper to prevent it from dropping SA B3M0657C A Bolt A B Bolt B 19 Remove bolt A 20 While slowly lowering transmission jack move rear differential forward and remove front member and rear differential from body G3M1029 DI 26 REAR DIFFERENTIAL FOR T TYPE 21 Remove rear differential from front member G3M1030 B INSTALLATION To install reverse the removal sequence 1 Install the air breather cap tapping with a plastic hammer CAUTION Be sure to install new air breather cap 2 Position front member on body by passing it un der parking breake cable and securing to rear dif ferential NOTE When installing rear differential front member do not confuse the installation sequence of the upper and lower stoppers 3 Install DOJ of drive shaft into rear differen tial lt Ref to DI 59 REPLACEMENT Rear Differ ential Side Oil Seal gt ST 28099PA090 SIDE OIL SEAL PROTEC TOR PKA a G3M1026 4 Installing procedure hereafter is in reverse order of removal 5 After installation fill differential carrier with gear oil to the filler plug level algi NOTE Apply flu
47. nt bearing Readjust or replace Readjust or replace 3 Insufficient or improper oil used Replace seized part and fill with specified oil to specified level 3 Damage NOTE Damaged parts should be replaced and also other parts should be thoroughly checked for any defect and should be re paired or replaced as required 4 Noises when starting or shifting gears NOTE Noises may be caused by differential as sembly universal joint wheel bearing etc Find out what is actually making noise before disassembly 1 Improper backlash for hypoid gear 2 Insufficient or excessive preload for side rear or front bearing Replace Readjust or replace 3 Excessive backlash for differential gear 4 Loose bolts and nuts such as crown gear bolt Replace gear or thrust washer Retighten 5 Damage due to overloading 1 Excessive backlash for hypoid gear Replace Readjust 2 Excessive backlash for differential gear Replace gear or thrust washer 3 Insufficient preload for front or rear bearing Readjust 4 Loose drive pinion nut 5 Loose bolts and nuts such as side bearing retainer attaching bolt Tighten to specified torque Tighten to specified torque 5 Noises when cornering 1 Damaged differential gear 2 Excessive wear or damage of thrust washer Replace Replace 3 Broken pinion mate shaft Replace 4 Se
48. oad B3M1904 DI 13 DIFFERENTIALS GENERAL DESCRIPTION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398177700 INSTALLER e Used for installing rear bearing cone e For T type B3M1905 398457700 ATTACHMENT e Used for removing side bearing retainer e For T type B3M1906 398477703 DRIFT2 e Used for press fitting the bearing race rear of differential carrier e For T type B3M1907 398437700 DRIFT e Used for installing side oil seal B3M1908 DI 14 e For T type GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507702 DUMMY SHAFT e Used for adjusting pinion height and preload e For T type B3M1909 398507703 DUMMY COLLAR e Used for adjusting pinion height and preload e For T type B3M1910 398517700 REPLACER e Used for removing rear bearing cone e For T type B3M1911 398487700 DRIFT e Used for press fitting the side bearing cone B3M1912 DI 15 e For T type DIFFERENTIALS GENERAL DESCRIPTION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS B3M1913 398507701 DIFFERENTIAL CARRIER GAUGE e Used for adjusting pinion height e For T type B3M1914 398527700 PULLEY ASSY e Used for removing front oil seal e Used for removing side bearing cup T type B3M1915A 398527700 PULLER SET e Used for extracting side bearing cone 1 BOLT 899521412 2 PULLER 399527702
49. of rear drive shaft VA type DI 22 DIFFERENTIAL GEAR OIL 2 Differential Gear Oil A INSPECTION 1 Take out filler plug and replace gear oil if it is contaminated or deteriorated lt Ref to DI 23 RE PLACEMENT Differential Gear Oil gt 2 Check gear oil level is up tp the bottom part of fill er bolt If the level is low refill up to the bottom of filler bolt S3M0527A A Filler plug B Drain plug B REPLACEMENT 1 Disconnect ground terminal from battery 2 Jack up vehicle and support it with sturdy racks 3 Remove the oil drain plug and filler plug and drain the gear oil CAUTION Be careful not to burn your hands because gear oil becomes extremely hot after running E D OA o mar ey A OO DR0003 4 Tighten oil drain plug NOTE Apply fluid packing to drain plug in T type e VA type uses a new aluminum gasket sl yO A Filler plug B Drain plug Fluid packing THREE BOND 1105 or equivalent DIFFERENTIALS Tightening torque T type 49 0 N m 5 0 kgf m 36 2 ft lb VA type 34 Nm 3 5 kgf m 25 3 ft lb 5 Fill differential carrier with gear oil to the upper plug level CAUTION Carefully refill oil while watching the level Ex cess or insufficient oil must be avoided Oil capacity 0 8 2 0 8 US gt 0 7 Imp qt DR0003 6 Install filler plug CAUTION
50. ove rear exhaust pipe and muffler Non turbo model without OBD lt Ref to EX SOHCw oOBD 13 REMOVAL Rear Exhaust Pipe and lt Ref to EX SOHCw oOBD 14 REMOVAL Muffler gt Non turbo model with OBD lt Ref to EX SOHC 11 REMOVAL Rear Exhaust Pipe and lt Ref to EX SOHC 12 REMOVAL Muffler gt Turbo model lt Ref to EX DOHC TURBO 13 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX DOHC TURBO 14 REMOVAL Muffler gt 8 Remove the DOJ of rear drive shaft from rear dif ferential 1 Remove the ABS sensor cable clamp and parking brake cable clamp from bracket Sas ABS sensor cable clamp L r Parking bake cable clamp EE EF 2 3 4 H3M1397A 2 Remove the ABS sensor cable clamp from the trailing link ABS sensor cable clamp H3M1398A DIFFERENTIALS 3 Remove the ABS sensor cable clamp and parking brake cable guide from the trailing link Parking brake cable guide ABS sensor cable LL clamp H3M1399A Stabilizer link H3M1396A 5 Remove the bolts which secure the trailing link to the housing G3M0042 6 Remove the bel which secure the front and rear lateral link to the rear housing G3M0043 7 Remove the DOJ from the rear differential with tire lever CAUTION When removing the DOJ from the rear differen tial fit tire lever to the bolt as shown in figure so as not to dameg
51. ower bracket T6 100 10 2 73 8 Non turbo model DI 9 GENERAL DESCRIPTION DIFFERENTIALS C CAUTION e Wear working clothing including a cap protec tive goggles and protective shoes during opera tion s Remove contamination including dirt and corro sion before removal installation or disassembly e Keep the disassembled parts in order and pro tect them from dust or dirt e Before removal installation or disassembly be sure to Clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each part on the vehicle is hot after running e Use SUBARU genuine gear oil grease etc or the equivalent Do not mix gear oil grease etc with that of another grade or from other manufacturers e Be sure to tighten fasteners including bolts and nuts to the specified torque s Place shop jacks or safety stands at the specified points e Apply gear oil onto sliding or revolution surfaces before installation e Before installing O rings or snap rings apply suf ficient amount of gear oil to avoid damage and de formation Before securing a part on a vice place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vice gt Avoid damaging the mating face of the case DI 10 GENERAL DESCRIPTION DIFFERENTIALS D PREPARATION TOOL 1 SPECIAL TOOLS TOOL NUMBER DESCRIPTION REMARKS HANDLE Used fo
52. pping at tooth ends re ENE De G3M0098B Adjustment Increase thickness of drive pinion height adjusting washer in order to bring drive pinion closer to crown gear center G3M0098F Flank contact Backlash is too small This may cause noise and stepped wear on surfaces AA EEA G3M0098C Reduce thickness of drive pinion height adjusting washer in order to move drive pinion away from crown gear pa G3M0098G Toe contact Contact area is small This may cause chipping at toe ends rna a G3M0098D Adjust as for flank contact pa G3M0098G Heel contact mb Adjusting direction of drive pinion o gt Adjusting direction of crown gear Contact area is small This may cause chipping at heel ends a eo E GSMOOSBE DI 54 Adjust as for face contact G3MO0098F REAR DIFFERENTIAL FOR VA TYPE 21 Install rear cover and tighten bolts to specified torque Tightening torque 25 N m 2 5 kgf m 18 1 ft lb S3M0526A A Rear cover E INSPECTION Wash all the disassembled parts clean and exam ine them for wear damage or other defects Re pair or replace defective parts as necessary 1 Crown gear and drive pinion e If abnormal tooth contact is evident find out the cause and adjust to give correct tooth contact at as sembly Replace the gear if excessively worn or in capable of adjustment s If crack score or seizure is evident repla
53. r 383745200 2 51 0 0988 C Preload adjusting washer 383755200 2 49 0 0980 l Preload adjustin 4 Turn ST1 with hand to make it seated and washer a 383765200 2 47 0 0972 tighten drive pinion nut while measuring the pre 383775200 2 45 0 0965 load with spring balance Select preload adjust 383785200 2 43 0 0957 ing washer and spacer so that the specified 383795200 2 41 0 0949 preload is obtained when nut is tightened to the 383805200 2 39 0 0941 specified torque 383815200 2 37 0 0933 CAUTION 383825200 2 35 0 0925 Use a new lock nut 383835200 2 33 0 0917 NOTE 383845200 2 31 0 0909 e Be careful not to give excessive preload Part No Length mm in e When tightening the drive pinion nut lock ST1 383695201 56 2 2 213 with ST2 as shown in the figure Ee 383695202 56 4 2 220 Preload adjusting ST1 398507704 BLOCK anses 383695203 56 6 2 228 ST2 398507702 DUMMY SHAFT 383695204 56 8 2 236 Tightening torque 383695205 57 0 2 244 383695206 57 2 2 252 181 Nm 18 5 kgf m 134 ft lb 3 Adjusting drive pinion height Adjust drive pinion height with shim installed be tween 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 eS Front and rear bearing preload For new bearing G3M1038 19 6 28 4 N 2 0 2 9 kgf 4 4 6 4 Ib at companion flange bolt hole Front and rear bearing prelo
54. r installing front and rear bearing cone ILLUSTRATION 398477701 B3M1893 Used press fitting the bearing cone of differential 398477702 carrier rear B3M1894 398217700 ATTACHMENT SET Stand for rear differential carrier disassembly and assembly Pie 2 B3M1895 498447120 Used for installing front oil seal B3M1896 DI 11 DIFFERENTIALS GENERAL DESCRIPTION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498427200 FLANGE WRENCH Used for stopping rotation of companion flange when loosening and tightening self lock nut B3M1897 398467700 DRIFT Used for removing pinion pilot bearing and front bearing cone B3M1898 399780104 WEIGHT Used for installing front bearing cone pilot bear ing companion flange B3M1899 899580100 INSTALLER Used for press fitting the front bearing cone pilot B3M1900 DI 12 bearing GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock REMOVER pin B3M1901 498247001 MAGNET BASE e Used for measuring backlash between side gear and pinion and hypoid gear e Used with DIAL GAUGE 498247100 B3M1902 498247100 DIAL GAUGE e Used measurng backlash between side gear and pinion hypoid gear e Used with MAGNET BASE 498247001 B3M1903 398507704 BLOCK Used for adjusting pinion height and prel
55. re re moved NOTE e Replace broken or cracked O ring with new one e Replace broken or corroded side retainer shim with new one of same thickness Side bearing retainer shim Thickness mm 0 20 0 0079 Part No 383475201 383475202 0 25 0 0098 383475203 0 30 0 0118 383475204 0 40 0 0157 383475205 0 50 0 0197 4 Align arrow marked on differential carrier with that marked on side retainer during installa tion CAUTION Be careful that side bearing outer race is not damaged by bearing roller in 3M0172B A Arrow mark 5 Tighten side bearing retainer bolts CAUTION Before tightening the two side bearing retainer bolts apply Lock Tite to bolt threads Lock Tite THREE BOND 1105 or equivalent Tightening torque 10 3 N m 1 05 kgf m 7 6 ft lb S3M0173 DIFFERENTIALS 6 Measure the crown gear to drive pinion backlash Set magnet base on differential carri er Align contact point of dial gauge with tooth face of crown gear and move crown gear while holding drive pinion still Read value indicated on dial gauge Backlash 0 10 0 20 mm 0 0039 0 0079 in G3M1047 7 Atthe same time measure the turning resis tance of drive pinion Compared with the resis tance when differential case is not installed if the increase of the resistance is not within the specified range readjust side bearing retainer s
56. the side gear Side gear backlash 0 1 0 2 mm 0 004 0 008 in If side gear backlash is not within the specification adjust clearance as specified by selecting side gear thrust washer B3M1934 2 CROWN GEAR BACKLASH Using a dial gauge check the backlash of the crown gear Crown gear backlash 0 1 0 2 mm 0 004 0 008 in If crown gear backlash is not within the specifica tion adjust the side bearing preload or repair if nec essary G3M1047 DI 38 REAR DIFFERENTIAL FOR T TYPE 3 CROWN GEAR RUNOUT Using a dial gauge check the crown gear runout Crown gear runout Less than 0 05 mm 0 0020 in If the crown gear runout exceeds 0 05 mm 0 0020 in replace the crown gear S3M0525 4 TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION Inspect tooth contact between crown gear and driv en pinion lt Ref to DI 30 ASSEMBLY Rear Differ ential for T type gt 5 TOTAL PRELOAD Using a gauge check the turning resistance in crease Total preload 2 9 10 8 N m 0 3 1 1 kgf 0 7 2 4 Ib If the increase of the resistance is not within the specification adjust the side bearing retainer shims B3M1935 DIFFERENTIALS F ADJUSTMENT 1 SIDE GEAR BACKLASH Adjust side gear backlash lt Ref to DI 30 ASSEMBLY Rear Differential for T type gt 2 CROWN GEAR BACKLASH Adjust crown gear backlash lt Ref to DI 30 ASSEM
57. ype 49 N m 5 0 kgf m 36 2 ft lb VA type 33 Nm 3 4 kgf m 24 6 ft lb 7 Jack up rear wheels and support the vehicle body with sturdy racks 8 Remove rear exhaust pipe and muffler 9 Remove propeller shaft from body lt Ref to DS 16 REMOVAL Propeller Shaft gt B3M1606 DIFFERENTIALS 10 Remove self locking nut while holding compan ion flange with ST ST 498427200 FLANGE WRENCH B3M1608A 11 Remove tank cover x 7 f a a B3M1643 12 Extract companion flange using ST ST 399703602 PULLEY ASSY B3M1644B 13 Remove oil seal using ST ST 499705401 PULLER ASSY ST B3M1609B DI 57 REAR DIFFERENTIAL FRONT OIL SEAL DIFFERENTIALS 14 Fit a new oil seal using ST ST 498447120 DRIFT G3M0037 15 Install companion flange NOTE Use a plastic hammer to install companion flange 16 Tighten self locking nut within the specified torque range so that the turning resistance of com panion flange becomes the same as that before re placing oil seal ST 498427200 FLANGE WRENCH NOTE Use a new self locking nut Tightening torque 181 4 N m 18 50 kgf m 133 8 ft lb G3M0034 17 Reassembling procedure hereafter is the re verse of the disassembling DI 58 REAR DIFFERENTIAL SIDE OIL SEAL 7 Rear Differential Side Oil Seal A REPLACEMENT 1 T TYPE 1 Disconnect ground terminal
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