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Subaru Impreza 2.5 L 2004 Owner's Manual
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Subaru Impreza 2.5 L 2004 Owner's Manual

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DIFFERENTIALS

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Summary of Contents for Subaru Impreza 2.5 L 2004

  • Page 1 DIFFERENTIALS...
  • Page 2 GENERAL DESCRIPTION DIFFERENTIALS 1. General Description A: SPECIFICATIONS When replacing a rear differential assembly, select the correct one according to the following table. NOTE: Using the different rear differential assembly causes the drive line and tires to “drag” or emit abnormal noise when AWD is selected.

  • Page 3: Service Data

    GENERAL DESCRIPTION DIFFERENTIALS 1. SERVICE DATA Except STi 18.1 — 38.8 (1.8 — 4.0, 4.1 — 8.7) Front and rear bearing preload at companion flange bolt model hole N (kgf, lb) STi model 24.1 — 38.6 (2.5 — 3.9, 5.4 — 8.7) Side gear backlash mm (in) 0.10 —...
  • Page 4 GENERAL DESCRIPTION DIFFERENTIALS Part No. Thickness mm (in) 383495200 3.09 (0.1217) 383505200 3.12 (0.1228) 383515200 3.15 (0.1240) 383525200 3.18 (0.1252) 383535200 3.21 (0.1264) 383545200 3.24 (0.1276) 383555200 3.27 (0.1287) 383565200 3.30 (0.1299) 383575200 3.33 (0.1311) Pinion height adjusting shim 383585200 3.36 (0.1323) 383595200 3.39 (0.1335)
  • Page 5 GENERAL DESCRIPTION DIFFERENTIALS Part No. Length mm (in) 383705200 2.59 (0.1020) 383715200 2.57 (0.1012) 383725200 2.55 (0.1004) 383735200 2.53 (0.0996) 383745200 2.51 (0.0988) 383755200 2.49 (0.0980) 383765200 2.47 (0.0972) Preload adjusting washer 383775200 2.45 (0.0965) 383785200 2.43 (0.0957) 383795200 2.41 (0.0949) 383805200 2.39 (0.0941) 383815200...
  • Page 6 GENERAL DESCRIPTION DIFFERENTIALS B: COMPONENT 1. REAR DIFFERENTIAL WITHOUT LSD ( 1 ) (18) (19) (21) ( 2 ) (20) ( 3 ) ( 4 ) (19) ( 5 ) (20) (18) (21) ( 1 ) (23) (22) (25) (26) (27) (16) (28)
  • Page 7 GENERAL DESCRIPTION DIFFERENTIALS 2. REAR DIFFERENTIAL WITH LSD (26) (21) (25) (22) (20) (23) (15) (19) (24) (13) (17) (18) (16) (14) (14) (15) (13) (16) (17) (10) (11) (12) DI-00347 Pinion crown gear and drive pin- (14) O-ring (25) Oil filler plug (Rear differential oil ion set temperature switch) (STi model)
  • Page 8 GENERAL DESCRIPTION DIFFERENTIALS 3. REAR DIFFERENTIAL MOUNTING SYSTEM DI-00312 Differential front member Differential mount bracket Tightening torque: N·m (kgf-m, ft-lb) Plate Differential mount front cover T1: 20 (2.0, 14.5) Crossmember T2: 33 (3.4, 24.3) Differential rear member T3: 65 (6.6, 47.9) Differential mount lower bracket T4: 70 (7.1, 51.6) Stopper...
  • Page 9 • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Use SUBARU genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with that of another grade or from other manufacturers.
  • Page 10 GENERAL DESCRIPTION DIFFERENTIALS D: PREPARATION TOOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398477701 HANDLE Used for installing front and rear bearing cone. ST-398477701 398477702 DRIFT Used press-fitting the bearing cone of differential carrier (rear). ST-398477702 398217700 ATTACHMENT SET Stand for rear differential carrier disassembly and assembly.
  • Page 11 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498427200 FLANGE WRENCH • Used for stopping rotation of companion flange when loosening and tightening self-lock nut. • For except STi model. ST-498427200 398467700 DRIFT Used for removing pinion, pilot bearing and front bearing cone.
  • Page 12 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock REMOVER pin. ST-899904100 498247001 MAGNET BASE • Used for measuring backlash between side gear and pinion, and hypoid gear. • Used with DIAL GAUGE (498247100). ST-498247001 498247100 DIAL GAUGE...
  • Page 13 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398177700 INSTALLER Used for installing rear bearing cone. ST-398177700 398457700 ATTACHMENT Used for removing side bearing retainer. ST-398457700 398477703 DRIFT2 Used for press-fitting the bearing race (rear) of differential carrier. ST-398477703 398437700 DRIFT Used for installing side oil seal.
  • Page 14 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507702 DUMMY SHAFT Used for adjusting pinion height and preload. ST-398507702 398507703 DUMMY COLLAR Used for adjusting pinion height and preload. ST-398507703 398517700 REPLACER Used for removing rear bearing cone. ST-398517700 398487700 DRIFT Used for press-fitting the side bearing cone.
  • Page 15 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507701 DIFFERENTIAL Used for adjusting pinion height. CARRIER GAUGE ST-398507701 398527700 PULLER ASSY • Used for removing front oil seal. • Used for removing side bearing cup. ST-398527700 398227700 WEIGHT Used for installing side bearing. ST-398227700 28099PA090 OIL SEAL PROTEC-...
  • Page 16 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398237700 GAUGE Used for installing side bearing. ST-398237700 28099PA100 DRIVE SHAFT Used for removing rear drive shaft from rear dif- REMOVER ferential. ST28099PA100 399703600 PULLER ASSY Used for removing companion flange. ST-399703600 899874100 INSTALLER Used for installing companion flange.
  • Page 17 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18759AA000 PULLER ASSY Used for removing side bearing cone of differen- (Newly adopted tool) tial. ST18759AA000 ST18759AA000 498937110 HOLDER DRIVE • Used for installing pilot bearing. PINION • For STi model. (This special tool is used for current automatic transmis- sion.)
  • Page 18 GENERAL DESCRIPTION DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 18633AA000 WRENCH COMPL • Used for stopping rotating of companion (Newly adopted tool) flange when loosening and tightening self-lock- ing nut. • For STi model. ST18633AA000 2. GENERAL PURPOSE TOOLS TOOL NAME REMARKS Transmission jack Used for assembly/disassembly of rear differential.
  • Page 19 DIFFERENTIAL GEAR OIL DIFFERENTIALS 2. Differential Gear Oil B: REPLACEMENT 1) Jack-up the vehicle and support it with sturdy A: INSPECTION racks. 1) Disconnect the oil temperature switch connec- 2) Disconnect the oil temperature switch connec- tor. (STi model) tor. (STi model) DI-00348 DI-00348 (A) Connector...

  • Page 20: Differential Gear Oil

    DIFFERENTIAL GEAR OIL DIFFERENTIALS 5) Fill the differential carrier with gear oil to the up- 7) Connect the oil temperature switch connector. per plug level. (STi model) NOTE: • Carefully refill oil while watching the level. Ex- cess or insufficient oil must be avoided. •...

  • Page 21: Front Differential

    FRONT DIFFERENTIAL DIFFERENTIALS 3. Front Differential A: NOTE 1. AT MODEL For front differential of AUTOMATIC TRANSMIS- SION, refer to “AT” section. <Ref. to 4AT-108, Front Differential.> 2. MT MODEL For front differential of manual transmission, refer to “5MT” or “6MT” section. <Ref. to 5MT-68, Front Differential Assembly.>...
  • Page 22 REAR DIFFERENTIAL DIFFERENTIALS 4. Rear Differential 14) Remove the clamps and bracket of parking brake cable. A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Move the select lever or gear shift lever to “N”. 4) Release the parking brake.
  • Page 23 REAR DIFFERENTIAL DIFFERENTIALS 17) Remove the lower bracket. 20) Remove the bolts which secure the rear differ- ential front member to body. Loosen the bolt A first, then remove the bolts B. NOTE: Support the front member with use of a helper to prevent it from dropping.
  • Page 24 REAR DIFFERENTIAL DIFFERENTIALS B: INSTALLATION ST 398217700 ATTACHMENT 1) Install the air breather cap tapping with a plastic hammer. NOTE: Be sure to install a new air breather cap. 2) Position the front member on body by passing it under the parking brake cable and securing to rear differential.
  • Page 25 REAR DIFFERENTIAL DIFFERENTIALS 5) Make right and left side bearing retainers in or- 8) Extract the bearing cone with ST. der to identify them at reassembly. Remove the NOTE: side bearing retainer attaching bolts, set the ST to • Do not attempt to disassemble the parts unless differential case, and extract right and left side necessary.
  • Page 26 REAR DIFFERENTIAL DIFFERENTIALS 11) Draw out the pinion mate shaft and remove the 14) Press the end of drive pinion shaft and extract it pinion mate gears, side gears and thrust washers. together with the rear bearing cone, preload adjust- (Model without LSD) ing spacer and washer.
  • Page 27 REAR DIFFERENTIAL DIFFERENTIALS 17) Remove the pilot bearing together with front ST 398217700 ATTACHMENT bearing cone using ST. ST 398467700 DRIFT DI-00061 2) Drain the gear oil by removing the plug. DI-00076 3) Remove the air breather cap. NOTE: (A) Pilot bearing •...
  • Page 28 REAR DIFFERENTIAL DIFFERENTIALS 5) Make right and left side bearing retainers in or- 8) Extract the bearing cone with ST. der to identify them at reassembly. Remove the NOTE: side bearing retainer attaching bolts, set the ST to • Do not attempt to disassemble the parts if unnec- differential case, and extract right and left side essary.
  • Page 29 REAR DIFFERENTIAL DIFFERENTIALS 11) Extract the companion flange with a puller. 14) Remove the front oil seal from differential carri- er using ST. ST 398527700 PULLER ASSY DI-00072 12) Press the end of drive pinion shaft and extract it DI-00075 together with the rear bearing cone, preload adjust- ing spacer and washer.
  • Page 30 REAR DIFFERENTIAL DIFFERENTIALS D: ASSEMBLY (2) Install the front bearing race to differential carrier using ST1 and ST2. 1. EXCEPT STi MODEL ST1 398477701 HANDLE ST2 398477703 DRIFT 2 NOTE: (3) Insert the ST1 into carrier with pinion height • Assemble in the reverse order of disassembling. adjusting washer and rear bearing cone fitted •...
  • Page 31 REAR DIFFERENTIAL DIFFERENTIALS NOTE: Thickness Part No. • Use a new lock nut. mm (in) • Be careful not to give excessive preload. 383705200 2.59 (0.1020) • When tightening the drive pinion nut, lock ST1 383715200 2.57 (0.1012) with ST2 as shown in the figure. 383725200 2.55 (0.1004) •...
  • Page 32 REAR DIFFERENTIAL DIFFERENTIALS (2) Measure the clearance N between the end Pinion height adjusting shim of ST2 and end surface of ST1 by using a thick- Part No. Thickness mm (in) ness gauge. 383575200 3.33 (0.1311) NOTE: 383585200 3.36 (0.1323) Make sure there is no clearance between the case 383595200 3.39 (0.1335)
  • Page 33 REAR DIFFERENTIAL DIFFERENTIALS 5) Press-fit the front bearing cone into case with 8) Press-fit the companion flange with ST1 and ST1, ST2 and ST3. ST2. ST1 398507703 DUMMY COLLAR NOTE: ST2 399780104 WEIGHT Be careful not to damage the bearing. ST3 899580100 INSTALLER ST1 899874100...
  • Page 34 REAR DIFFERENTIAL DIFFERENTIALS • Insert the pinion mate shaft into the differential 11) Install the crown gear on differential case. case by aligning the lock pin holes. NOTE: Before installing the bolts, apply Lock Tite to bolt threads. Lock Tite: THREE BOND 1324 (Part No.
  • Page 35 REAR DIFFERENTIAL DIFFERENTIALS (2) Install the differential case assembly into dif- Tightening torque: ferential carrier in the reverse order of disas- 10.3 N·m (1.05 kgf-m, 7.6 ft-lb) sembly. DI-00098 DI-00065 (6) Measure the crown gear-to-drive pinion (3) Install the side retainer shims to the right backlash.
  • Page 36 REAR DIFFERENTIAL DIFFERENTIALS 16) Check the crown gear runout on its back sur- • Face contact face, and make sure that pinion and crown gear ro- Checking item: Backlash is too large. tate smoothly. Contact pattern Limit of runout: Less than 0.05 mm (0.0020 in) AT-00208 Corrective action: Increase thickness of drive pin- ion height adjusting shim in order to bring drive pin-...
  • Page 37 REAR DIFFERENTIAL DIFFERENTIALS Corrective action: Reduce thickness of drive pinion Contact pattern height adjusting shim in order to move drive pinion away from crown gear. AT-00211 Corrective action: Increase thickness of drive pin- AT-00213 ion height adjusting shim in order to bring drive pin- •...
  • Page 38 REAR DIFFERENTIAL DIFFERENTIALS 23) Tighten the side bearing retainer bolts. • Replace the oil seal with a new one at every dis- assembly. Apply chassis grease between the lips Lock Tite: when installing the oil seal. THREE BOND 1105 (Part No. 004403010) or equivalent Tightening torque: 10.3 N·m (1.05 kgf-m, 7.6 ft-lb)
  • Page 39 REAR DIFFERENTIAL DIFFERENTIALS 4) Pinion height adjusting shim selection. Pinion height adjusting shim (1) Measure the thickness of inserted pinion Part No. Thickness T mm (in) height adjusting shim. 38336AA280 3.24 (0.1276) 38336AA290 3.27 (0.1287) 38336AA300 3.30 (0.1299) 38336AA310 3.33 (0.1311) 38336AA320 3.36 (0.1323) 38336AA330...
  • Page 40 REAR DIFFERENTIAL DIFFERENTIALS 7) Insert the spacer, then press-fit the pilot bearing Bearing preload: with STs. 24.1 — 38.6 N (2.5 — 3.9 kgf, 5.4 — 8.7 lb) ST1 399780104 WEIGHT ST2 899580100 INSTALLER ST3 398507703 DUMMY COLLER ST4 498937110 HOLDER DRIVE PINION DI-00117 11) If bearing preload is out of specification, adjust...
  • Page 41 REAR DIFFERENTIAL DIFFERENTIALS 13) Extract the companion flange with a puller. ST 18633AA000 WRENCH COMPL DI-00072 DI-00071 14) Fit a new oil seal with ST. 17) Install the crown gear on differential case. NOTE: NOTE: • Press-fit until the end of oil seal is 1 mm (0.04 in) Before installing the bolts, apply Lock Tite to bolt inward from end of carrier.
  • Page 42 REAR DIFFERENTIAL DIFFERENTIALS ST 398417700 DRIFT NOTE: Be careful that side bearing outer race is not dam- aged by bearing roller. DI-00324 (2) Install the oil seal. <Ref. to DI-50, RE- DI-00097 PLACEMENT, Rear Differential Side Oil Seal.> 20) Adjusting side bearing retainer shims (A) Arrow mark (1) The driven gear backlash and side bearing preload can be determined by the side bearing...
  • Page 43 REAR DIFFERENTIAL DIFFERENTIALS (7) At the same time, measure the total preload • Correct tooth contact of drive pinion. Compared with the resistance Checking item: Tooth contact pattern is slightly when differential case is not installed, if the total shifted toward to toe side under no-load preload is not within the specified range, read- rotation.
  • Page 44 REAR DIFFERENTIAL DIFFERENTIALS • Flank contact Corrective action: Reduce thickness of drive pinion Checking item: Backlash is too small. height adjusting shim in order to move drive pinion away from crown gear. Contact pattern AT-00213 AT-00209 • Heel contact (Outside end contact) Corrective action: Reduce thickness of drive pinion Checking item: Contact area is small.
  • Page 45 REAR DIFFERENTIAL DIFFERENTIALS 27) Align the arrow mark on differential carrier with 30) Install the breather cap. the mark on side retainer during installation. 31) Install the drain plug and rear differential oil temperature switch or oil temperature sensor. Tightening torque: 49 N·m (5.0 kgf-m, 36.2 ft-lb) E: INSPECTION Wash all the disassembled parts clean, and exam-...
  • Page 46 REAR DIFFERENTIAL DIFFERENTIALS 1. SIDE GEAR BACKLASH 3. CROWN GEAR RUNOUT Using a dial gauge, check the backlash of the side Using a dial gauge, check the crown gear runout. gear. Crown gear runout: Side gear backlash: Less than 0.05 mm (0.0020 in) 0.1 —...
  • Page 47 REAR DIFFERENTIAL DIFFERENTIALS F: ADJUSTMENT 1. SIDE GEAR BACKLASH Adjust the side gear backlash. <Ref. to DI-30, AS- SEMBLY, Rear Differential.> 2. CROWN GEAR BACKLASH Adjust the crown gear backlash. <Ref. to DI-30, ASSEMBLY, Rear Differential.> 3. TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION Adjust the tooth contact between crown gear and drive pinion gear.

  • Page 48: Rear Differential Front Oil Seal

    REAR DIFFERENTIAL FRONT OIL SEAL DIFFERENTIALS 5. Rear Differential Front Oil 11) Remove the tank cover. Seal A: REPLACEMENT 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Move the select lever or gear shift lever to “N”. 4) Release the parking brake.
  • Page 49 REAR DIFFERENTIAL FRONT OIL SEAL DIFFERENTIALS 15) Install the companion flange. NOTE: Use a plastic hammer to install the companion flange. 16) Tighten the self-locking nut within the specified torque range so that the preload of companion flange becomes the same as that before replacing oil seal.

  • Page 50: Rear Differential Side Oil Seal

    REAR DIFFERENTIAL SIDE OIL SEAL DIFFERENTIALS 6. Rear Differential Side Oil Seal (3) Remove the ABS wheel speed sensor cable clamp and parking brake cable guide from trail- A: INSPECTION ing link. Make sure that there is no oil leakage from side oil seal.
  • Page 51 REAR DIFFERENTIAL SIDE OIL SEAL DIFFERENTIALS (7) Remove the DOJ from the rear differential 10) Remove the oil seal using ST. by using ST. ST 398527700 PULLER ASSY NOTE: When removing the DOJ from rear differential, fit ST to the bolts as shown in the figure so as not to damage the side bearing retainer.
  • Page 52 REAR DIFFERENTIAL SIDE OIL SEAL DIFFERENTIALS ST 28099PA090 SIDE OIL SEAL PROTEC- DI-00060 (3) Remove the ST. ST 28099PA090 SIDE OIL SEAL PROTEC- 13) Hereafter, reassemble in the reverse order of disassembly. DI-52...

  • Page 53: Rear Differential Member

    REAR DIFFERENTIAL MEMBER DIFFERENTIALS 7. Rear Differential Member ST 28099PA090 SIDE OIL SEAL PROTEX- A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Move the selector lever or gear shift lever to “N”. 4) Release the parking brake.

  • Page 54: General Diagnostic Table

    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 Repair or replace. front or side oil seal. Scored, battered, or excessively worn sliding surface of com- panion flange.
  • Page 55 GENERAL DIAGNOSTIC TABLE DIFFERENTIALS Symptom or trouble Possible cause Remedy 6. Gear noises (1) Improper tooth contact of hypoid gear. Readjust or replace the hypoid gear set. NOTE: (2) Improper backlash for hypoid gear. Readjust. Since noises from engine, muffler, trans- (3) Scored or chipped teeth of hypoid Replace the hypoid gear set.
  • Page 56 GENERAL DIAGNOSTIC TABLE DIFFERENTIALS DI-56...

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