Subaru IMPREZA 2004 Service Manual page 40

MANUAL TRANSMISSION AND DIFFERENTIAL
3) Install a new O-ring.
E: INSPECTION
Repair or replace the front differential in following
cases.
• Each gear is damaged, seized, or excessively
worn.
• Sliding surfaces of the differential case is dam-
aged, seized or excessively worn.
• Bearings and bearings part is damaged, rusted
or worn.
• Bearings that fail to turn smoothly or make ab-
normal noise when turned.
1. HYPOID GEAR BACKLASH
Check the hypoid gear backlash. If it is not within
specifications, adjust it. <Ref. to 6MT-108, HY-
POID GEAR BACKLASH, Front Differential As-
sembly.>
2. TOOTH CONTACT OF HYPOID GEAR
1) Be sure the hypoid gear backlash is within spec-
ifications. If it is not within specifications, adjust it.
<Ref. to 6MT-108, HYPOID GEAR BACKLASH,
Front Differential Assembly.>
2) Apply a uniform thin coat of red lead on both
tooth surfaces of three or four teeth of the hypoid
driven gear.
3) Install the drive pinion shaft assembly, and then
secure with four bolts.
NOTE:
Use the old gasket and washer to prevent the mat-
ing surface of housing from damaging.
Front Differential Assembly
Tightening torque:
4) Rotate the drive pinion shaft to right and left for
several times.
5) Remove the drive pinion shaft assembly, and
then check tooth contact. If tooth contact is inaccu-
rate, adjust it. <Ref. to 6MT-101, ADJUSTMENT,
Drive Pinion Shaft Assembly.>
• Correct tooth contact.
NOTE:
Under no load, tooth contacts 50—60% from center
AT-00219
to toe side (tooth contact shifts to heel side when
driving).
F: ADJUSTMENT
1. HYPOID GEAR BACKLASH
1) Install the right and left side retainer.
ST1 499787000
ST2 18630AA000 WRENCH ASSY (LEFT SIDE)
NOTE:
Screw in the right side retainer a bit further than left
side.
2) Install the drive pinion shaft assembly, and then
secure with four bolts.
NOTE:
Use the old gasket and washer to prevent the mat-
ing surface of housing from damaging.
Tightening torque:
3) Using the ST, screw in the left side retainer until
the drive pinion and hypoid driven gear contacts
MT-00652
lightly. Then loosen the right side retainer.
ST1 499787000
ST2 18630AA000 WRENCH ASSY (LEFT SIDE)
4) Using the ST, rotate the drive pinion shaft sever-
al times.
6MT-108
50 N·m (5.0 kgf-m, 36.9 ft-lb)
(B)
(A) Toe side
(B) Heel side
WRENCH ASSY (RIGHT
SIDE)
50 N·m (5.0 kgf-m, 36.9 ft-lb)
WRENCH ASSY (RIGHT
SIDE)
(A)
AT-00207