SUBARU LEGACY 1996 Service Repair Manual

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

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) Install the air breather cap tapping with a plastic ham-
mer.
CAUTION:
Be sure to install new air breather cap.
2) Position front member on body by passing it under park-
ing brake cable and securing to rear differential.
NOTE:
When installing rear differential front member, do not con-
fuse the installation sequence of the upper and lower stop-
pers.
G3M1026
3) Install DOJ of rear drive shaft into rear differential. to 3-4 [W2A2].>
ST 28099PA090 SIDE OIL SEAL PROTECTOR
G3M1051
4) Installing procedure hereafter is in the reverse order of
removal.
5) After installation, fill differential carrier with gear oil to
the upper plug level.
CAUTION:
Apply fluid packing to plug.
Fluid packing:
THREE BOND 1205 or equivalent
Oil capacity:
0.8
(0.8 US qt, 0.7 Imp qt)
Tightening torque:
44±4 N⋅m (4.5±0.4 kg-m, 32.5±2.9 ft-lb)
37
3-4SERVICE PROCEDURE
2. Rear Differential

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

8) Remove rear differential front member.
NOTE:
When removing rear differential front member, work the
removal procedure as rear differential.

38
3-4SERVICE PROCEDURE
3. Rear Differential Front Member

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 installing rear differential front member, do not con-
fuse the installation sequence of the stopper.
G3M1026
2) Insert DOJ of rear drive shaft into rear differential.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
CAUTION:
Before inserting, replace the differential side oil seal
and the circlip at the end of the spline shaft with a new
one.
3) Installing procedure hereafter is in the reverse order of
removal.
39
3-4SERVICE PROCEDURE
3. Rear Differential Front Member

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

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