SUBARU LEGACY 1999 Service Repair Manual

Adjust 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
G3M0083
(2) Measure the clearance ªNº between the end
of ST2 and the end surface of ST1 by using a
thickness gauge.
NOTE:
Make sure there is no clearance between ST2 and
ST1.
ST1 498447150 DUMMY SHAFT
ST2 498505501 DIFFERENTIAL CARRIER
GAUGE
H3M1309A
(3) Obtain the thickness of pinion height adjust-
ing washer to be inserted from the following
formula, and replace the temporarily installed
shim with this one.NOTE:
Use 1 to 3 shims as required for adjustment.
T=To+Nþ0.05 (mm)
where
T = Thickness of pinion height adjusting shim (mm)
To = Thickness of shim originally installed (mm)
N = Reading of thickness gauge (mm)
(Example of calculation)
To = 0.15 mm
N = 0.1 mm
T = 0.15 + 0.1 þ 0.05 = 0.2 mm
Result: Thickness = 0.2 mm
Therefore use the 32295AA220.
Pinion height adjusting shim
Part No. Thikness mm (in)
32295AA200
32295AA210
32295AA220
32295AA230
32295AA240
32295AA2500.150 (0.0059)
0.175 (0.0069)
0.200 (0.0079)
0.225 (0.0089)
0.250 (0.0098)
0.275 (0.0108)
41
[W2E2]3-4SERVICE PROCEDURE
2. Rear Differential

4) Install the selected pinion height adjusting shim
on drive pinion, and press the rear bearing cone
into position with ST.
ST 498175500 INSTALLER
G3M0084
5) Insert drive pinion into differential carrier, install
the previously selected bearing preload adjusting
spacer and washer.
H3M1666A
(A) Drive pinion
(B) Adjusting spacer
(C) Washer
(D) Differential carrier
6) Press-fit front bearing cone into case with ST1,
ST2 and ST3.
ST1 32285AA000 DUMMY COLLAR
ST2 399780104 WEIGHT
ST3 899580100 INSTALLER
G3M0085
7) Insert spacer, then press-fit pilot bearing with
ST1 and ST2.
ST1 399780104 WEIGHT
ST2 899580100 INSTALLER
G3M0719
8) Fit a new oil seal with ST.
NOTE:
IPress-fit until end of oil seal is 1 mm (0.04 in)
inward from end of carrier.
IApply grease between the oil seal lips.
ST 498447120 OIL SEAL INSTALLER
G3M0087
9) Press-fit companion flange with ST1 and ST2.
CAUTION:
Be careful not to damage bearing.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT
G3M0720
42
3-4[W2E2]SERVICE PROCEDURE
2. Rear Differential

10) Install self-locking nut. Then tighten self-lock-
ing nut with ST.
ST 398427700 FLANGE WRENCH
Tightening torque:
188
±26 N´m (19.2±2.7 kg-m, 139±20 ft-lb)
G3M0721
11) Assembling differential case
(1) Install side gears and pinion mate gears,
with their thrust washers and pinion mate shaft,
into differential case.
NOTE:
IApply gear oil on both sides of the washer and
on the side gear shaft before installing.
IInsert the pinion mate shaft into the differential
case by aligning the lock pin holes.
G3M0089
(2) Measure the clearance between differential
case and the back of side gear.
(3) Adjust the clearance as specified by select-
ing side gear thrust washer.
Side gear backlash:
0.05 Ð 0.15 mm (0.0020 Ð 0.0059 in)
Side gear thrust washer
Part No. Thickness mm (in)
803135011
803135012
803135013
803135014
8031350150.925 Ð 0.950 (0.0364 Ð 0.0374)
0.950 Ð 0.975 (0.0374 Ð 0.0384)
0.975 Ð 1.000 (0.0384 Ð 0.0394)
1.000 Ð 1.025 (0.0394 Ð 0.0404)
1.025 Ð 1.050 (0.0404 Ð 0.0413)
(4) Check the condition of rotation after apply-
ing oil to the gear tooth surfaces and thrust sur-
faces.
(5) After driving in pinion shaft lock pin, stake
the both sides of the hole to prevent pin from
falling off.
(6) nstall crown gear on differential case.
NOTE:
Tighten diagonally while tapping the bolt heads.
Tightening torque:
62
±5 N´m (6.3±0.5 kg-m, 45.6±3.6 ft-lb)
G3M0069
12) Press side bearing cone onto differential case
with ST.
ST 498485400 DRIFT
G3M0091
13) Assemble holders.
43
[W2E2]3-4SERVICE PROCEDURE
2. Rear Differential

(1) Install oil seal into right and left holders.
ST 498447100 AXLE SHAFT OIL SEAL
INSTALLER
G3M0092
(2) Install bearing race into right and left hold-
ers.
ST 398477702 BEARING OUTER RACE
DRIFT
G3M0093
(3) Install the differential case assembly into
differential carrier in the reverse order of disas-
sembly.
G3M0065
14) Perform adjustment of backlash of pinion
crown gear set and adjustment of preload of differ-
ential side bearing.(1) Turn drive pinion with ST for better fitting of
differential side bearing.
ST 498427200 FLANGE WRENCH
G3M0094
(2) Screw in left-side holder until light contact is
made with ST.
ST 399780111 WRENCH
G3M0064
(3) Back off side (left-side) holder approxi-
mately 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
44
3-4[W2E2]SERVICE PROCEDURE
2. Rear Differential

(5) Measure the crown gear-to-drive pinion
backlash. Set magnet base on differential car-
rier. 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.
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.
Backlash:
0.10 Ð 0.15 mm (0.0039 Ð 0.0059 in)
G3M0095
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.
G3M0096
16) Tighten bolt of lock plate to specified torque.
Tightening torque:
25
±3 N´m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
G3M0063
17) Re-check crown gear-to-pinion backlash.
Backlash:
0.10 Ð 0.15 mm (0.0039 Ð 0.0059 in)
G3M0095
18) 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)
G3M0097
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 ªTooth
contact patternº.
NOTE:
Be sure to wipe off red lead completely after
adjustment is completed.
20) If proper tooth contact is not obtained, once
again adjust the drive pinion height and the differ-
ential side bearing preload (mentioned above) and
the hypoid gear backlash.
45
[W2E2]3-4SERVICE PROCEDURE
2. Rear Differential

(1) Drive pinion height
ST1 498447150 DUMMY SHAFT
ST2 498505501 DIFFERENTIAL CARRIER
GAUGE
H3M1309A
T=To+Nþ0.05 (mm)
where
T = Thickness of pinion height adjusting shim (mm)
To = Thickness of shim originally inserted (mm)
N = Reading of thickness gauge (mm)
(2) Differential side bearing preload
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 399780111 WRENCH
G3M0064
(3) Hypoid gear backlash
Backlash:
0.10 Ð 0.15 mm (0.0039 Ð 0.0059 in)
G3M0095
46
3-4[W2E2]SERVICE PROCEDURE
2. Rear Differential

Adjusting direction of drive pinion
Adjusting direction of crown gear
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.)
G3M0098A
Ð
Face contact
Backlash is too large.This may cause noise and chipping at
tooth ends.
G3M0098B
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.
G3M0098C
Reduce thickness of drive pinion height
adjusting washer in order to move drive
pinion away from crown gear.
G3M0098G
Toe contact Contact area is small.
This may cause chipping at toe ends.
G3M0098D
Adjust as for flank contact.
G3M0098G
Heel contact Contact area is small.
This may cause chipping at heel ends.
G3M0098E
Adjust as for face contact
G3M0098F
F: INSTALLATION
To install, reverse the removal sequence.
1) Install the air breather cap tapping with a plas-
tic hammer.CAUTION:
Be sure to install new air breather cap.
2) Position front member on body by passing it
under parking brake cable and securing to rear
differential.
47
[W2F0]3-4SERVICE PROCEDURE
2. Rear Differential

NOTE:
When installing rear differential front member, do
not confuse the installation sequence of the upper
and lower stoppers.
3) Install DOJ of rear drive shaft into rear differen-
tial.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
G3M1026
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:
IApply fluid packing to plug (T-type).
IUse a new aluminum gasket when installing
the plug (VA-type).
Fluid packing:
THREE BOND 1105 or equivalent
Oil capacity:
0.8
(0.8 US qt, 0.7 Imp qt)
Tightening torque:
T-type;
44
±4 N´m (4.5±0.4 kg-m, 32.5±2.9 ft-lb)
VA-type;
34
±4 N´m (3.5±0.4 kg-m, 25.3±2.9 ft-lb)
G3M1051
3. Rear Differential Front
Member
A: REMOVAL
1. T-TYPE
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to ªNº.
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.

8) Remove muffler.

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

2. VA-TYPE
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to ªNº.
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.

8) Remove muffler.

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

B: INSTALLATION
1. T-TYPE
To install, reverse the removal sequence.
48
3-4[W3A1]SERVICE PROCEDURE
3. Rear Differential Front Member

NOTE:
When installing rear differential front member, do
not confuse the installation sequence of the upper
and lower stoppers.
3) Install DOJ of rear drive shaft into rear differen-
tial.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
G3M1026
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:
IApply fluid packing to plug (T-type).
IUse a new aluminum gasket when installing
the plug (VA-type).
Fluid packing:
THREE BOND 1105 or equivalent
Oil capacity:
0.8
(0.8 US qt, 0.7 Imp qt)
Tightening torque:
T-type;
44
±4 N´m (4.5±0.4 kg-m, 32.5±2.9 ft-lb)
VA-type;
34
±4 N´m (3.5±0.4 kg-m, 25.3±2.9 ft-lb)
G3M1051
3. Rear Differential Front
Member
A: REMOVAL
1. T-TYPE
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to ªNº.
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.

8) Remove muffler.

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

2. VA-TYPE
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to ªNº.
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.

8) Remove muffler.

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

B: INSTALLATION
1. T-TYPE
To install, reverse the removal sequence.
48
3-4[W3A1]SERVICE PROCEDURE
3. Rear Differential Front Member

1) Position front member on body by passing it
under parking brake cable and securing to rear
differential.
NOTE:
When installing rear differential front member, do
not confuse the installation sequence of the stop-
per.
G3M0058
2) Insert DOJ of rear drive shaft into rear differen-
tial.

CAUTION:
Before inserting, replace the differential side
oil seal with a new one.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
G3M0049
3) Installing procedure hereafter is in the reverse
order of removal.
2. VA-TYPE
To install, reverse the removal sequence.1) Position front member on body by passing it
under parking brake cable and securing to rear
differential.
NOTE:
When installing rear differential front member, do
not confuse the installation sequence of the stop-
per.
G3M1029
2) Insert DOJ of rear drive shaft into rear differen-
tial.

CAUTION:
Before inserting, replace the differential side
oil seal with a new one.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
G3M1026
3) Installing procedure hereafter is in the reverse
order of removal.
49
[W3B2]3-4SERVICE PROCEDURE
3. Rear Differential Front Member