Subaru Legacy 2003 Service Manual page 2716

8. General Diagnostic Table
A: INSPECTION
Symptom or trouble
1. Oil leakage
2. Seizure
NOTE:
Seized or damaged parts should be re-
placed, and also other parts should be
thoroughly checked for any defect and
should be repaired or replaced as re-
quired.
3. Damage
NOTE:
Damaged parts should be replaced, and
also other parts should be thoroughly
checked for any defect and should be re-
paired or replaced as required.
4. Noises when starting or shifting
gears
NOTE:
Noises may be caused by differential as-
sembly, 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, trans-
mission, 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 coast-
ing, 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, try-
ing to pick up only differential noise.
GENERAL DIAGNOSTIC TABLE
Possible cause
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 side retainer, or incor-
rectly fitted O-ring.
Loose rear cover attaching bolts or dam-
aged gasket.
Loose oil filler or drain plug.
Wear, damage or incorrectly fitting for
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.
Vibrating differential carrier.
DI-61
DIFFERENTIALS
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 specified
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.
Replace.