General Diagnostic Table - Subaru Legacy 2002 Service Manual

Differentials

8. General Diagnostic Table

A: INSPECTION
Symptom or trouble
1. Oil leakage
2. Seizure
NOTE:
Seized or damaged parts should be
replaced, and also other parts should be
thoroughly checked for any defect and
should be repaired or replaced as
required.
3. Damage
NOTE:
Damaged parts should be replaced, and
also other parts should be thoroughly
checked for any defect and should be
repaired or replaced as required.
4. Noises when starting or shifting
gears
NOTE:
Noises may be caused by differential
assembly, universal joint, wheel bearing,
etc. Find out what is actually making
noise before disassembly.
5. Noises when cornering
6. Gear noises
NOTE:
Since noises from engine, muffler,
transmission, propeller shaft, wheel
bearings, tires, and body are sometimes
mistaken for noises from differential
assembly, be careful in checking them.
Inspection methods to locate noises
include coasting, accelerating, cruising,
and jacking-up all four wheels. Perform
these inspections according to condition
of trouble. When listening to noises, shift
gears into four wheel drive and fourth
speed position, trying to pick up only dif-
ferential noise.
GENERAL DIAGNOSTIC TABLE
S303257
S303257A10
Worn, scratched, or incorrectly seated
front or side oil seal. Scored, battered, or
excessively worn sliding surface of com-
panion flange.
Clogged or damaged air breather.
Loose bolts on differential spindle or side
retainer, or incorrectly fitted O-ring.
Loose rear cover attaching bolts or dam-
aged gasket.
Loose oil filler or drain plug.
Wear, damage or incorrectly fitting for
spindle, side retainer and oil seal.
Insufficient backlash for hypoid gear.
Excessive preload for side, rear, or front
bearing.
Insufficient or improper oil used.
Improper backlash for hypoid gear.
Insufficient or excessive preload for side,
rear, or front bearing.
Excessive backlash for differential gear.
Loose bolts and nuts such as crown
gear bolt.
Damage due to overloading.
Excessive backlash for hypoid gear.
Excessive backlash for differential gear.
Insufficient preload for front or rear bear-
ing.
Loose drive pinion nut.
Loose bolts and nuts such as side bear-
ing retainer attaching bolt.
Damaged differential gear.
Excessive wear or damage of thrust
washer.
Broken pinion mate shaft.
Seized or damaged side bearing.
Improper tooth contact of hypoid gear.
Improper backlash for hypoid gear.
Scored or chipped teeth of hypoid gear.
Seized hypoid gear.
Improper preload for front or rear bear-
ings.
Seized, scored, or chipped front or rear
bearing.
Seized, scored, or chipped side bearing. Replace.
Vibrating differential carrier.
Possible cause
DI-62
Remedy
Repair or replace.
Clean, repair or replace.
Tighten bolts to specified torque.
Replace O-ring.
Tighten bolts to specified torque.
Replace gasket and apply liquid packing.
Retighten and apply liquid packing.
Repair or replace.
Readjust or replace.
Readjust or replace.
Replace seized part and fill with speci-
fied oil to specified level.
Replace.
Readjust or replace.
Replace gear or thrust washer.
Retighten.
Replace.
Readjust.
Replace gear or thrust washer.
Readjust.
Tighten to specified torque.
Tighten to specified torque.
Replace.
Replace.
Replace.
Replace.
Readjust or replace hypoid gear set.
Readjust.
Replace hypoid gear set.
Replace hypoid gear set.
Readjust.
Replace.
Replace.