SUBARU LEGACY 1995 Service Repair Manual

G3M0036
9) Remove oil seal using ST.
ST 499705401 PULLER ASSY
G3M0037
10) Fit a new oil seal using ST.
ST 498447120 OIL SEAL INSTALLER
G3M0034
11) Install companion flange.
12) Tighten self-locking nut within the specified torque
range so that the turning resistance of companion flange
becomes the same as that before replacing oil seal.
ST 498427200 FLANGE WRENCH
CAUTION:
Use a new self-locking nut.
Tightening torque:
181.4±14.7 N⋅m (18.50±1.50 kg-m, 133.8±10.8 ft-lb)
13) Reassembling procedure hereafter is the reverse of
the disassembling.
15
3-4SERVICE PROCEDURE
2. Rear Differential

2. SIDE OIL SEAL
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to“N”.
3) Release the parking brake.
4) 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.

G3M0038
8) Remove the DOJ of rear drive shaft from rear differen-
tial.
(1) Remove the A.B.S. sensor cable clamp and park-
ing brake cable clamp from bracket.
G3M0039
(2) Remove the A.B.S. sensor cable clamp from the
trailing link.
G3M0040
(3) Remove the A.B.S. sensor cable clamp and park-
ing brake cable guide from the trailing link.
G3M0041
(4) Remove the rear stabilizer link.
16
3-4SERVICE PROCEDURE
2. Rear Differential

G3M0042
(5) Remove the bolts which secure the trailing link to
the rear housing.
G3M0043
(6) Remove the bolts which secure the front and rear
lateral link to the rear housing.
G3M1020
(7) Remove crossmember reinforcement lower (AWD
Sedan only).
(8) Remove the DOJ from the rear differential by using
ST.
ST 208099PA100 DRIVE SHAFT REMOVER
G3M1021
CAUTION:
When removing the DOJ from the rear differential, fit
tire lever to the bolt as shown in figure so as not to
damage the side bearing retainer.
G3M1022
9) Secure rear drive shaft to rear crossmember using wire.
17
3-4SERVICE PROCEDURE
2. Rear Differential

G3M1023
10) Remove side oil seal with ST.
ST 398527700 PULLER ASSY
G3M1024
11) Drive in a new side oil seal with ST.
CAUTION:
Apply chassis grease between the oil seal lips.
ST 398437700 DRIFT
G3M1025
12) Insert the DOJ into rear differential.
(1) Install ST to rear differential.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
G3M1026
(2) Insert the spline shaft until the spline portion is
inside the side oil seal.
(3) Remove ST.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
13) Hereafter, re-assemble in reverse order of disassem-
bly.
18
3-4SERVICE PROCEDURE
2. Rear Differential

B: 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-up vehicle and support it with sturdy racks.
6) Remove wheels.
7) Remove rear exhaust pipe and muffler.

G3M0021
8) Remove front exhaust cover.
G3M0022
9) Remove front cover of rear differential mount.
G3M0024
10) Remove propeller shaft.
CAUTION:
When removing propeller shaft, pay attention not to
damage the sliding surfaces of rear drive shaft (exten-
sion) spline, oil seal and sleeve yoke.
NOTE:
Prepare an oil can and cap since the transmission oil flows
out from the extension at removing propeller shaft.
G3M0026
NOTE:
Insert the cap into the extension to prevent transmission oil
from flowing out immediately after removing the propeller
shaft.
19
3-4SERVICE PROCEDURE
2. Rear Differential

G3M0053
11) Remove heat sealed cover.
12) Remove clamps and bracket of parking brake cable.
13) Remove crossmember reinforcement lower (AWD
Sedan only).
G3M1020
14) Remove DOJ of rear drive shaft from rear differential
using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
G3M1022
15) Secure rear drive shaft to rear crossmember using
wire.
G3M0054
16) Remove lower differential bracket.
G3M0055
17) Support rear differential with transmission jack.
20
3-4SERVICE PROCEDURE
2. Rear Differential

G3M1028
18) Remove self-locking nuts connecting rear differential
to rear crossmember.
G3M0057
19) Remove bolts which secure rear differential front
member to body.
Loosen bolt

1first, then remove bolts
2.
NOTE:
Support front member with the use of a helper to prevent
it from dropping.
20) Remove bolt

1.
G3M1029
21) While slowly lowering transmission jack, move rear
differential forward and remove front member and rear dif-
ferential from body.
G3M1030
22) Remove rear differential from front member.
21
3-4SERVICE PROCEDURE
2. Rear Differential

C: DISASSEMBLY
To detect real cause of trouble, inspect the following items
before disassembling.
Tooth contact of crown gear and pinion, and backlash
Runout of crown gear at its back surface
Turning resistance of drive pinion
G3M1031
1) Set ST on vise and install the differential assembly to
ST.
ST 398217700 ATTACHMENT
2) Drain gear oil by removing plug.
G3M1033
3) Remove the air breather cap.
NOTE:
Do not attempt to replace the air breather cap unless nec-
essary.
G3M1032
4) Remove rear cover by loosening retaining bolts.
G3M1034
5) Make right and left side bearing retainers in order to
identify them at reassembly. Remove side bearing retainer
attaching bolts, set ST to differential case, and extract right
and left side bearing retainers with a puller.
ST 398457700 ATTACHMENT
CAUTION:
Each shim, which is installed to adjust the side bear-
ing preload, should be kept together with its mating
retainer.
22
3-4SERVICE PROCEDURE
2. Rear Differential

G3M1035
6) Pull out differential assembly from differential carrier.
CAUTION:
Be careful not to hit the teeth against the case.
G3M1036
7) When replacing side bearing, pull bearing cup from side
bearing retainer using ST.
ST 398527700 PULLER ASSY
G3M0068
8) Extract bearing cone with ST.
CAUTION:
Do not attempt to disassemble the parts unless neces-
sary.
NOTE:
Set puller so that its claw catch the edge of the bearing
cone.
Never mix up the right and left hand bearing cups and
cones.
ST 399527700 PULLER SET
G3M0069
9) Remove crown gear by loosening crown gear bolts.
CAUTION:
Further disassembling is not allowed.
B3M0133
10) Drive out pinion shaft lock pin from crown gear side.
NOTE:
The lock pin is staked at the pin hole end on the differen-
tial carrier; do not drive it out forcibly before unstaking it.
ST 899904100 STRAIGHT PIN REMOVER
23
3-4SERVICE PROCEDURE
2. Rear Differential

G3M1052
11) Hold companion flange with ST and remove drive pin-
ion nut.
ST 498427200 FLANGE WRENCH
G3M0073
12) Extract the companion flange with a puller.
G3M0074
13) 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
G3M0071
14) 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.
G3M0072
15) Hold companion flange with ST and remove drive pin-
ion nut.
ST 498427200 FLANGE WRENCH
24
3-4SERVICE PROCEDURE
2. Rear Differential