Subaru Impreza 2002 Service Manual page 409

MANUAL TRANSMISSION AND DIFFERENTIAL
F: ADJUSTMENT
1. BEVEL PINION GEAR BACKLASH
1) Measure the bevel pinion gear backlash. <Ref.
to 6MT-113, BEVEL PINION GEAR BACKLASH,
INSPECTION, Front Differential Assembly.>
2) Disassemble the differential case. <Ref. to 6MT-
110, DIFFERENTIAL CASE, DISASSEMBLY,
Front Differential Assembly.>
3) Select a washer from the following table, and
then assemble the differential case. <Ref. to 6MT-
112, DIFFERENTIAL CASE, ASSEMBLY, Front
Differential Assembly.>
(D)
(A)
(A) Pinion shaft
(B) Bevel pinion gear
(C) Bevel gear
(D) Washer
NOTE:
If the backlash is excessive, select a thicker shim. If
the backlash is insufficient, select a thinner new
shim.
Washer
Part No.
803038021
803038022
803038023
FRONT DIFFERENTIAL ASSEMBLY
(B)
(C)
(D)
(C)
(B)
TR0823
Thickness mm (in)
0.925 — 0.950
(0.0364 — 0.0374)
0.975 — 1.000
(0.0384 — 0.0394)
1.025 — 1.050
(0.0404 — 0.0413)
2. HYPOID GEAR BACKLASH
1) Install the right and left side retainer.
ST1 499787000
ST2 18630AA000 WRENCH ASSY (LEFT SIDE)
NOTE:
Screw in the right side retainer a bit further than left
side.
2) Install the drive pinion shaft assembly, and then
secure with four bolts.
NOTE:
Use the old gasket and washer to prevent the mat-
ing surface of housing from damaging.
Tightening torque:
69 N·m (7.0 kgf-m, 50.9 ft-lb)
3) Using the ST, screw in the left side retainer until
the drive pinion and hypoid driven gear contacts
lightly. Then loosen the right side retainer.
ST1 499787000
ST2 18630AA000 WRENCH ASSY (LEFT SIDE)
4) Using the ST, rotate the drive pinion shaft sever-
al times.
ST 18631AA000 HANDLE
5) Repeat step 3) and 4) until the left side retainer
can not be rotated. For the right side retainer,
screw in until the inner race and outer race contacts
lightly. This condition is "0" backlash.
6) Mark an engagement point on the right and left
side retainer and clutch housing.
7) Return the left side retainer for three teeth, and
screw in the right side retainer for three teeth.
6MT-114
WRENCH ASSY (RIGHT
SIDE)
WRENCH ASSY (RIGHT
SIDE)
TR0817
TR0828