Subaru Impreza 2003 Service Manual page 2247

E: INSPECTION
Wash all the disassembled parts clean, and exam-
ine them for wear, damage, or other defects. Re-
pair or replace defective parts as necessary.
1) Crown gear and drive pinion
• If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact at as-
sembly. Replace the gear if excessively worn or in-
capable of adjustment.
• If crack, score, or seizure is evident, replace as a
set. Slight damage of tooth can be corrected by oil
stone or the like.
2) Side gear and pinion mate gear
• Replace if crack, score, or other defects are evi-
dent on tooth surface.
• 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 dis-
assembling.
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 lip contacting surfaces have
flaws.
1. SIDE GEAR BACKLASH
Using a dial gauge, check the backlash of the side
gear.
Side gear backlash:
0.05 — 0.15 mm (0.0020 — 0.0059 in)
If the side gear backlash is not within the specifica-
tion, adjust the side gear backlash as specified by
selecting the side gear thrust washer.
REAR DIFFERENTIAL FOR VA-TYPE
DI-00240
DI-67
2. CROWN GEAR BACKLASH
Using a dial gauge, check the backlash of the
crown gear.
Crown gear backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
If the crown gear backlash is not within the specifi-
cation, adjust the side bearing preload or repair if
necessary.
3. CROWN GEAR RUNOUT
Using a dial gauge, check the crown gear runout.
Crown gear runout:
Less than 0.05 mm (0.0020 in)
If the crown gear runout exceeds 0.05 mm (0.0020
in), replace the crown gear.
4. TOOTH CONTACT BETWEEN CROWN
GEAR AND DRIVE PINION
Inspect the tooth contact between crown gear and
drive pinion.
<Ref. to DI-58, ASSEMBLY, Rear Differential for
VA-type.>
DIFFERENTIALS
DI-00099
DI-00101