Rear diff SUBARU TRIBECA 2009 1.G Service Owner's Guide

DI-25
Rear Differential (VA–type)
DIFFERENTIALS
15) Perform the backlash adjustment between the
hypoid driven gear and drive pinion, and preload
adjustment of differential side bearing.
(1) Turn the drive pinion with ST for better fitting
of differential side bearing.
ST 498427200 FLANGE WRENCH
(2) Screw in the side holder LH until light con-
tact is made with ST.
ST 18630AA010 WRENCH
(3) Back off the holder on the hypoid driven
gear side by approx.1 and 1/2 teeth, and tighten
the other side holder by approx. 2 teeth (amount
that the hypoid driven gear is turned back (1
and 1/2) + 1/2 teeth).
[Back off amount of side (hypoid driven gear
side) holder + 1/2 tooth.] This + 1/2 tooth gives
preload.
(4) Temporarily tighten the lock plate.
NOTE:
Turn over the lock plate to shift the holder by 1/2
tooth.
(5) Measure the hypoid driven gear-to-drive
pinion backlash. Set the magnet base on differ-
ential carrier. Align the contact point of dial
gauge with tooth face of hypoid driven gear, and
move hypoid driven gear while holding drive
pinion still. Read the value indicated on dial
gauge.
NOTE:
If measured value of backlash is not within the
specified range, repeat the procedures for pinion
driven gear set backlash adjustment and the differ-
ential side bearing preload adjustment.
Backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
16) Put alignment marks on both the differential
carrier and holder. Remove the holder side at a
time.
Replace them in the original position after inserting
an O-ring and applying grease to the threaded por-
tion.
DI-00385
ST
ST
DI-00399
DI-00364
(A) Alignment mark
(B) Holder
DI-00172
DI-00386
(B)
(A)

DI-26
Rear Differential (VA–type)
DIFFERENTIALS
17) Tighten the bolt of lock plate to specified
torque.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
18) Recheck the hypoid driven gear to pinion back-
lash.
Backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
19) Checking and adjusting the tooth contact of hy-
poid driven gear
(1) Apply an even coat of red lead on both sides
of three or four teeth on the hypoid driven gear.
Check the contact pattern after rotating the hy-
poid driven gear several revolutions back and
forth until a definite contact pattern appears on
the hypoid driven gear.
(2) When the contact pattern is not correct, re-
adjust.
NOTE:
Be sure to wipe off the red lead completely after the
adjustment is completed.
•Correct tooth contact
Check item: Tooth contact pattern is slightly
shifted towards the toe side under no-load rota-
tion. (When driving it will move toward the heel
side.)
•Face contact
Check item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of drive pin-
ion height adjusting washer in order to bring drive
pinion close to hypoid driven gear.
DI-00364
DI-00172
(A) Toe side
(B) Heel side
MT-01401
(A)
(B)
AT-00208
AT-00212

DI-27
Rear Differential (VA–type)
DIFFERENTIALS
•Flank contact
Check item: Backlash is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion
height adjusting washer according to the procedure for
bringing drive pinion away from hypoid driven gear.
•Toe contact (inner side contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion
height adjusting washer according to the procedure
for bringing drive pinion away from hypoid driven gear.
•Heel contact (outside end contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Increase thickness of drive pin-
ion height adjusting washer in order to bring drive
pinion close to hypoid driven gear.
20) If proper tooth contact is not obtained, once
again adjust the drive pinion height and the differ-
ential side bearing preload (already mentioned)
and the hypoid gear backlash.
21) Attach a new gasket, rear cover, and ground
stay to the differential carrier.
Tightening torque:
34 N·m (3.5 kgf-m, 25.1 ft-lb)
22) Using new gaskets, install the rear differential
oil temperature switch.
Tightening torque:
60 N·m (6.1 kgf-m, 44.3 ft-lb)
AT-00209
AT-00213
AT-00210
AT-00213
AT-00211
AT-00212
DI-00477

DI-28
Rear Differential (VA–type)
DIFFERENTIALS
23) Affix with the attachment clip so that the white
marking of the hose is within the range of Z (87°).
E: INSPECTION
Wash all the disassembled parts clean, and exam-
ine them for wear, damage or other defects. Repair
or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
•If there is evidently an abnormal tooth contact,
find out the cause and adjust until the teeth contact
correctly. Replace the gear if there is an excessive
worn or an incapable adjustment.
•If crack, cutout or seizure is found, replace the
parts as a set. Slight damage of some teeth can be
corrected by oil stone or the like.
2) Side gear and pinion mate gear
•Replace the differential case assembly if cracks,
scoring or other defects are evident on tooth sur-
face.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, noise or other defect is evident.
4) Oil seal
Replace if deformed or damaged, and at every dis-
assembling.
5) Differential carrier
Replace if the bearing bores are worn or damaged.
6) Differential case
Replace if its sliding surfaces are worn or cracked.
7) Companion flange
Replace if the oil seal lip contact surface shows
cracking.
1. HYPOID DRIVEN GEAR BACKLASH
Using a dial gauge, check the backlash of hypoid
driven gear.
Hypoid driven gear backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or re-
pair if necessary.
2. TOOTH CONTACT BETWEEN HYPOID
DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between the hypoid driv-
en gear and drive pinion. BLY, Rear Differential (VA–type).>
3. COMPANION FLANGE
1) If rust or dirt is attached to the companion flange,
remove them.
2) Set a dial gauge at a companion flange surface
(mating surface of propeller shaft and companion
flange), and then measure the companion flange
runout.
Limit of runout:
0.08 mm (0.003 in)
(1) 0 — 1 mm (0 — 0.04 in)
(2) Marking
DI-00478
B
B
A
A
Z
(1)
(2)
DI-00099
DI-00360

DI-29
Rear Differential (VA–type)
DIFFERENTIALS
3) Set the gauge inside of the companion flange,
and measure the runout.
Limit of runout:
0.08 mm (0.003 in)
4) If either runout exceeds the limit, move the
phase of companion flange and drive pinion 90°
each, and find the point where the runout will be
within the limit.
5) If the runout exceeds the limit when changing
the phase, replace the companion flange and re-
check the runout.
6) If the runout exceeds the limit after replacing the
companion flange, the drive pinion may be assem-
bled incorrectly or bearing is faulty.
4. REAR DIFFERENTIAL OIL TEMPERA-
TURE SWITCH
Inspect the continuity of the rear differential oil tem-
perature switch.
F: ADJUSTMENT
1. HYPOID DRIVEN GEAR BACKLASH
Adjust hypoid driven gear backlash.
type).>
2. TOOTH CONTACT BETWEEN HYPOID
DRIVEN GEAR AND DRIVE PINION
Adjust the tooth contact between hypoid driven
gear and drive pinion gear.
type).>
Specified resistance Criteria
Less than 1 ΩNormal
1 MΩ or more Replacement
DI-00361
DI-00479

DI-30
Rear Differential Front Oil Seal
DIFFERENTIALS
5. Rear Differential Front Oil
Seal
A: INSPECTION
Make sure that there is no leakage from front oil
seal portion. If there is any leakage replace the oil
seal and inspect the propeller shaft.
B: REPLACEMENT
1) Release the parking brake.
2) Remove the oil drain plug, and drain gear oil.
3) Install the oil drain plug.
NOTE:
Use a new metal gasket.
Tightening torque:
29 N·m (3.0 kgf-m, 21.7 ft-lb)
4) Jack-up the rear wheel and support the body
with rigid racks.
5) Remove the rear exhaust pipe and muffler.
6) Remove the heat shield cover.
7) Remove the propeller shaft. MOVAL, Propeller Shaft.>
8) Remove the self-locking nut while holding the
companion flange with ST.
ST 498427200 FLANGE WRENCH
9) Extract the companion flange using ST.
ST 399703600 PULLER ASSY
10) Remove the oil seal using ST or screwdriver.
ST 398527700 PULLER ASSY
11) Install a new oil seal with ST.
ST 498447120 OIL SEAL INSTALLER
(A) Filler plug
(B) Drain plug
(A)
DI-00357
(B)
AT-03243
DI-00194
ST
DI-00196
ST
DI-00197
ST
DI-00292
ST

DI-31
Rear Differential Front Oil Seal
DIFFERENTIALS
12) Install the companion flange.
NOTE:
Use a plastic hammer to install companion flange.
13) Apply Lock Tite to the drive pinion shaft screw
threads and the nut seat surface.
Lock Tite:
THREE BOND 1324 (Part No. 004403042)
14) Tighten the self-locking nut within the specified
torque range so that the rotating resistance of com-
panion flange becomes the same as that of before
oil seal replacement.
ST 498427200 FLANGE WRENCH
NOTE:
Use a new self-locking nut.
Tightening torque:
191 N·m (19.5 kgf-m, 141 ft-lb)
15) Hereafter, reassemble in the reverse order of
disassembly.
DI-00194
ST

DI-32
Rear Differential Side Oil Seal
DIFFERENTIALS
6. Rear Differential Side Oil Seal
A: INSPECTION
Make sure that there is no leakage from side oil
seal. If there is any leakage, replace the oil seal.
B: REPLACEMENT
1) Remove the rear differential. MOVAL, Rear Differential (VA–type).>
2) Remove the rear differential side oil seal using a
screwdriver wrapped with vinyl tape to prevent the
side retainer from scratches.
3) Using the ST, install the oil seal to the side re-
tainer.
ST 398437700 DRIFT
4) Install the rear differential. STALLATION, Rear Differential (VA–type).>
ST
DI-00209

DI-33
Rear Differential Front Member
DIFFERENTIALS
7. Rear Differential Front Mem-
ber
A: REMOVAL
1) Disconnect the ground cable from the battery.
2) Jack-up the vehicle.
3) Support the rear differential using transmission
jack, and then remove the rear differential front
member.
B: INSTALLATION
Using new self-locking nuts, install the rear differ-
ential front member.
Tightening torque:
T1: 65 N·m (6.6 kgf-m, 48 ft-lb)
T2: 110 N·m (11.2 kgf-m, 81 ft-lb)
C: INSPECTION
1) Check the rear differential front member for
damage, bend and corrosion.
If damage, bend or corrosion is excessive, replace
the rear differential front member.
2) Check the bushings of rear differential member
for cracking, hardening and damage.
If cracking, hardening or damage is excessive, re-
place rear differential front member.
(A) Rear differential front member
DI-00293(A)
DI-00294
T2
T1

DI-34
General Diagnostic Table
DIFFERENTIALS
8. General Diagnostic Table
A: INSPECTION
Symptom or trouble Possible cause Remedy
1. Oil leakage(1) Worn, scratched, or incorrectly seated
front or side oil seal. Scored, battered or
excessively wor n sliding surface of com-
panion flange.
Correct or replace.
(2) Clogged or damaged air breather. Clean, repair or replace.
(3) Loose bolts on differential spindle or
side retainer, or incorrectly fitted O-ring.
Tighten the bolts to specified torque.
Replace the O-ring.
(4) Loose rear cover attaching bolts or
damaged gasket.
Tighten the bolts to specified torque.
Replace gasket and apply liquid gasket.
(5) Loose oil filler or drain plug. Retighten and apply liquid gasket.
(6) Wear, damage or incorrect fitting of
spindle, side retainer or oil seal.
Correct or replace.
2. Seizure
NOTE:Seized or damaged parts should be re-
placed, and also other parts should be thor-
oughly checked for any defect and should
be repaired or replaced as required.
(1) Insufficient backlash for hypoid gear. Readjust or replace.
(2) Excessive preload for side, rear or
front bearing.
Readjust or replace.
(3) Insufficient or improper oil used. Replace seized part and fill with speci-
fied 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.
(1) Improper backlash for hypoid gear. Replace.
(2) Insufficient or excessive preload for
side, rear or front bearing.
Readjust or replace.
(3) Excessive backlash for differential
gear.
Replace gear or thrust washer.
(4) Loose bolts and nuts such as hypoid
driven gear bolt
Retighten.
(5) Damage due to overloading. Replace.
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 be-
fore disassembling.
(1) Excessive backlash for hypoid gear. Readjust.
(2) Excessive backlash for differential
gear.
Replace the differential case assembly.
(3) Insufficient preload for front or rear
bearing.
Readjust.
(4) Loose drive pinion nut. Tighten to the specified torque.
(5) Loose bolts and nuts such as side
bearing retainer attaching bolt.
Tighten to the specified torque.
5. Noises when cornering(1) Damaged differential gear. Replace the differential case assembly.
(2) Excessive wear or damage of thrust
washer.
Replace the differential case assembly.
(3) Broken pinion mate shaft. Replace the differential case assembly.
(4) Seized or damaged side bearing. Replace.
6. Gear Noise
NOTE:
Since noises from engine, muffler, trans-
mission, propeller shaft, wheel bearings,
tires, and body are sometimes mistaken for
noises from differential assembly, be care-
ful in checking them. Inspection methods to
locate noises include coasting, accelerat-
ing, cruising, and jacking-up all four wheels.
Perform these inspections according to the
condition of trouble. When listening to nois-
es, shift gears into four wheel drive and
fourth speed position, trying to pick up only
differential noise.
(1) Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.
(2) Improper backlash of the hypoid gear. Readjust.
(3) Scored or chipped teeth of hypoid
gear.
Replace hypoid gear set.
(4) Seized hypoid gear. Replace hypoid gear set.
(5) Improper preload for front or rear
bearings.
Readjust.
(6) Seized, cut-away or chipped front or
rear bearing.
Replace.
(7) Seized, cut-away or chipped side
bearing.
Replace.
(8) Differential carrier is vibrating. Replace the differential case assembly.