diff SUBARU TRIBECA 2009 1.G Service Service Manual

DI-20
Rear Differential (VA–type)
DIFFERENTIALS
1) Adjusting preload for front and rear bearings
Adjust the bearing preload between front and rear
bearings with collar and washer. Pinion height ad-
justing washer is not affected by this adjustment.
The adjustment must not be carried out with oil seal
inserted.
(1) Install the rear bearing race into the differen-
tial carrier using ST1 and ST2.
ST1 398477701 HANDLE
ST2 398477703 DRIFT 2
(2) Using the ST, install the front bearing race to
the differential carrier.
ST 499277200 INSTALLER
(3) Insert the front bearing cone.
NOTE:
Use new front bearing cone.
(4) Measure and record the thickness of pinion
adjust washer.
NOTE:
If tooth contact (drive pinion, hypoid driven gear) is
normal in the inspection before disassembling, ver-
ify that the washer is not deformed, and then re-use
the used washer.
(5) Insert the ST1 into carrier with the pinion
height adjusting washer and rear bearing cone
fitted onto it.
NOTE:
Use new rear bearing cone.
(6) Install the preload adjusting collar & washer,
front bearing cone, collar, companion flange,
and washer & self-locking nut.
ST1 18678AA000 DUMMY SHAFT
(7) Turn ST1 by hand to seat the bearing, and
measure the initial load and initial torque with a
spring scale while tightening the selflocking nut.
Select the preload adjusting washer and collar
so that the specified preload is obtained when
nut is tightened to the specified torque.
NOTE:
•Use a new self-locking nut.
•Be careful not to give excessive preload.
•When tightening the self-locking nut, lock com-
panion flange with ST2 as shown in the figure.
•Measure the preload in direction of tangent to the
flange.
ST1 18678AA000 DUMMY SHAFT
ST2 498427200 FLANGE WRENCH
Tightening torque:
191 N·m (19.5 kgf-m, 141 ft-lb)
DI-00375
ST2
ST1
DI-00376
ST
(A) Pinion height adjusting washer
(B) Preload adjusting collar
(C) Preload adjusting washer
(D) Collar
ST1DI-00377
(D)(C)(B)(A)
DI-00398
ST2

DI-21
Rear Differential (VA–type)
DIFFERENTIALS
Initial load:
12.7—32.2 N (1.3—3.28 kgf, 2.9—7.24 lb)
Initial torque:
0.48 — 1.22 N·m (0.045—0.124 kgf-m, 0.32—
0.9 ft-lb)
2) Adjusting drive pinion height:
Adjust the drive pinion height with washer installed
between the rear bearing cone and the back of pin-
ion gear.
(1) Install the ST2.
ST1 18678AA000 DUMMY SHAFT
ST2 18831AA010 DIFFERENTIAL CARRIER
GAUGE
(2) Install the side holder LH to the left side of
the differential carrier in reverse direction.
Preload adjusting washer
Par t No. Thickness mm (in)
38336AA430 1.500 (0.0591)
38336AA440 1.513 (0.0596)
38336AA450 1.525 (0.0600)
38336AA460 1.538 (0.0606)
38336AA470 1.550 (0.0610)
38336AA480 1.563 (0.0615)
38336AA490 1.575 (0.0620)
38336AA500 1.588 (0.0625)
38336AA510 1.600 (0.0630)
38336AA520 1.613 (0.0635)
38336AA530 1.625 (0.0640)
38336AA540 1.638 (0.0645)
38336AA550 1.650 (0.0650)
38336AA560 1.663 (0.0655)
38336AA570 1.675 (0.0659)
38336AA580 1.688 (0.0665)
38336AA590 1.700 (0.0669)
38336AA600 1.713 (0.0674)
38336AA610 1.725 (0.0679)
38336AA620 1.738 (0.0684)
38336AA630 1.750 (0.0689)
38336AA640 1.763 (0.0694)
38336AA650 1.775 (0.0699)
DI-00152
DI-00481
Preload adjusting collar
Par t No. Length mm (in)
31454AA250 51.05 (2.010)
31454AA260 51.25 (2.018)
31454AA270 51.35 (2.022)
31454AA280 51.45 (2.026)
31454AA290 51.55 (2.030)
31454AA300 51.65 (2.033)
31454AA310 51.75 (2.037)
31454AA320 51.85 (2.041)
31454AA330 52.05 (2.049)
(A) Pinion height adjusting washer
RH
LH
N
(A)
ST2ST1
DI-00379
DI-00380

DI-22
Rear Differential (VA–type)
DIFFERENTIALS
(3) 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 18678AA000 DUMMY SHAFT
ST2 18831AA010 DIFFERENTIAL CARRIER
GAUGE
(4) Obtain the thickness of pinion height adjust-
ing washer to be inserted from the following for-
mula, and replace the temporarily installed
washer with this one.
NOTE:
Adjust it using the 0 — 3 washers.
T = To + N – 0.05 mm (0.0020 in)
(Example of calculation)
To = 0.15 mm (0.0020 in)
N = 0.1 mm (0.0039 in)
T = 0.15 mm (0.0020 in) + 0.1 mm (0.0039 in) –
0.05 mm (0.0020 in) = 0.2 mm (0.0079 in)
Result: Thickness = 0.2 mm (0.0079 in)
Therefore use part number 32295AA370.
3) Install the selected pinion height adjusting wash-
er on drive pinion, and press the rear bearing cone
into position with ST.
ST 398177700 INSTALLER
4) Insert the drive pinion into the differential carrier,
and install the preselected bearing preload adjust-
ing collar and washer.
5) Set ST and differential carrier to the press and
install the front bearing cone.
ST 399780104 WEIGHT
NOTE:
Set the carrier to the press until the companion
flange is installed.
TThickness of pinion height adjusting
washer mm (in)

To T h i c k n e s s o f w a s h e r t e m p o r a l l y
inserted mm (in)

NClearance of thickness gauge mm (in)
Memo:

Pinion height adjusting washer
Par t No. Thickness mm (in)
32295AA350 0.150 (0.0059)
32295AA360 0.175 (0.0069)
32295AA370 0.200 (0.0079)
32295AA380 0.225 (0.0089)
32295AA390 0.250 (0.0098)
32295AA400 0.275 (0.0108)
DI-00381
ST2
ST1
(A) Drive pinion
(B) Bearing preload adjusting collar
(C) Bearing preload adjusting washer
(D) Differential carrier
ST
DI-00085
(D)
(A)
(B)
(C)
DI-00382
ST
DI-00383

DI-23
Rear Differential (VA–type)
DIFFERENTIALS
6) Insert the collar, then install the pilot bearing.
7) Fit a new oil seal with ST.
NOTE:
•Press-fit until the oil seal end comes 1 mm (0.04
in) inward from end of carrier.
•Apply grease to the oil seal lips.
ST 499277200 INSTALLER
8) Press-fit the companion flange with ST.
NOTE:
Be careful not to damage the bearing.
ST 899874100 INSTALLER
9) Apply Lock-Tite to the drive pinion shaft screw
threads and on the new nut seat.
Lock Tite:
THREE BOND 1324 (Part No. 004403042)
10) Attach the nut and use the ST to fix the com-
panion flange in place, then tighten.
ST 498427200 FLANGE WRENCH
Tightening torque:
191 N·m (19.5 kgf-m, 141 ft-lb)
11) Measure the initial torque and initial load.
Initial load:
12.7—32.2 N (1.3—3.28 kgf, 2.9—7.24 lb)
Initial torque:
0.48 — 1.22 N·m (0.045—0.124 kgf-m, 0.32—
0.9 ft-lb)
(A) Pilot bearing
(B) Collar
DI-00389
(A)
(B)
ST
DI-00089
DI-00384
ST
DI-00372
ST
DI-00152
DI-00481

DI-24
Rear Differential (VA–type)
DIFFERENTIALS
12) Install the hypoid driven gear to differential
case.
NOTE:
•Tighten diagonally while tapping the bolt heads.
•Set a cushioning such as wooden block, alumi-
num plate or shop cloth between vise and differen-
tial case if the side gear comes into contact with
vise.
Tightening torque:
62 N·m (6.3 kgf-m, 45.6 ft-lb)
13) Press the side bearing into differential case us-
ing ST.
ST 398487700 DRIFT
14) Assemble holders.
(1) Install the new oil seal into holder RH and
LH.
ST 498447100 INSTALLER
(2) Install the bearing race into holder RH and
LH.
ST 398177700 INSTALLER
CAUTION:
Make sure that the RH and LH oil seals, bearing
outer races and cones are properly assembled.
(3) Install the differential assembly into differen-
tial carrier in the reverse order of disassembly.
(4) Temporally tighten the side holders RH and
LH in differential carrier to install.
DI-00371
ST
DI-00095
ST
DI-00166
ST
DI-00167
DI-00366

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