Subaru XT 1988 Service Manual page 736

4WD SYSTEM 3-4
INSPECTION
Wash all the disassembled parts clean, and examine them for
wear, damage, or other defects. Repair or replace defective
parts as necessary.
1) Drive gear and drive pinion
(1) If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact at assembly.
Replace the gear if excessively worn or incapable of
adjustment.
(2) If crack, score, or seizure is evident, replace as a set.
Slight damage of tooth can be corrected by oil stone or
the I ike.
A14-023
2) Side gear and pinion mate gear Fig. 46
(1) Replace if crack, score, or other defects are evident
on tooth surface.
(2) Replace if thrust washer contacting surface is worn or
seized. Slight damage of the surface can be corrected by
oil stone or the like.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging during rotation,
abnormal noise or other defect is evident.
4) Thrust washers of side gear and pinion mate gear
Replace if seizure, flaw, abnormal wear or other defect is
evident.
5) Oil seal
Replace if deformed or damaged, and at every disassembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal I ip contacting surfaces have flaws.
ASSEMBLY
2) Adjusting preload for front and rear bearings.
Adjust the bearing preload with spacer and washer between
front and rear bearings. Pinion height adjusting washer has
nothing to do with this adjustment. The adjustment must be
carried out without oil seal.
(1) Press front and rear bearing cups into differential
carrier.
HANDLE & DRIFT KIT
(397471600)
A14-024
1) Precautions for assembling Fig. 47
(1) Assemble in the reverse order of disassembling.
Check and adjust each part during assembly.
(2) Keep the shims and washers in order, so that they are
not misinstalled.
(3) Thoroughly clean the surfaces on which the shims,
washers and bearings are to be installed.
(4) Apply gear oil when install ing the bearings and thrust
washers.
(5) Be careful not to mix up the right and left hand cups
of the bearings.
(6) Replace the oil seal with new one at every dis-
assembly. Apply chassis grease between the lips (*) when
installing the oil seal.
23
(2) Insert DUMMY SHAFT (398507702) with pinion
height adjusting washer and rear bearing cone fitted on it
into carrier_
Reuse the used washer if they show normal tooth contact
pattern when checked before disassembly.