Subaru 1600 Service Manual page 256

MANUAL TRANSMISSION AND DIFFERENTIAL
3)
Differential
Assembly
1) Install differential side gears and
differential pinions together with
washers (35.1 x 45 x t mm) on differ·
ential case, and then insert differential
pinion shaft.
Pinion shaft
A12-261
Fig.
6·95
2) Measure backlash between gear
and pinion with Magnet Base (49824·
7001) and Dial Gauge (498247100).
If the backlash is inappropriate, make
adjustment by using proper washers.
Unit: mm (in)
1600
0.05 - 0.15
Standard
(0.0020 0.0059)
backlash
1800\ 0.13 - 0.18
i
(0.0051 - 0.(071)
\
Dial Gauge (4982471001
A 12·262
Fig.
6·96
Washers (35.1 x 45 x t mm)
Part No. Thickness mm (in)
803135011
0.925 - 0.950
(0.0364
0.0374)
I
803135012
0.950 - 0.975
(0.0374 - 0.0384)
803135013
0.975 - 1.000
(0.0384 - 0.0394)
803135014
1.000 1.025
(0.0394 - 0.0404)
803135015
1.025 - 1.050
(0.0404 0.0413)
3) Align the differential pinion shaft
hole with the holes on differential case
and drive straight pin (4
x
44 mm) by
tapping lightly with hammer from the
crown gear side. Finally drive pin until
it falls in about 1 mm (0.04 in) with
Remover (899904100).
NOTE:
Stake the hole portion after driving it
into the differential case.
Straight pin
A12-263
Fig.
6·97
4) Install bearing cone on differential
case with Installer (399790110) and
Seat (399520105).
NOTE:
Notice that the cups of roller bearings
are provided as a set.
6-39
2
Fig.
6·98
Installer (399790110)
Seat (399520105)
A12·067
5) Install crown gear on case.
11600
I
Install crown gear with lock washers.
Torque
NOTE:
57 -67N·m
(5.8 - 6.8 kg·m,
42 - 49 ft·lb)
I
a. Replaca lock washers with new
ones.
b. Bend lock washers to prevent bolts
from working loose after tightening
bolts.
Lock washer
Fig. 6·99
\1800 \
Install crown gear.
Torque
A12·035
57-67N·m
(5.8 - 6.8 kg-m,
42 - 49 ft·lb)
6) Install axle drive shafts and lock it
with snap rings. Select proper snap
ring so that the clearance between
differential pinion shaft and tip of axle
drive shaft is within the specified
range.