Subaru Legacy 2004 Service Manual page 2891

DIFFERENTIALS
18) If proper tooth contact is not obtained, once
again adjust the drive pinion height and the differ-
ential side bearing preload (already mentioned)
and the hypoid gear backlash.
19) Install the new gasket and rear cover to differ-
ential carrier and tighten the bolts to specified
torque.
Tightening torque:
!
25 N m (2.5 kgf-m, 18.1 ft-lb)
E: INSPECTION
Wash all the disassembled parts clean, and exam-
ine them for wear, damage and other defects. Re-
pair or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
• If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact. Re-
place the gear if excessively worn or incapable 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) Bearings
Replace if seizure, peeling, wear, rust, dragging
during rotation, 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.
Rear Differential (VA-type)
1. SIDE GEAR BACKLASH
Using a dial gauge, check the backlash of the side
gear. (VA1-type only)
Side gear backlash:
If the side gear backlash is not within the specifica-
tion, adjust it as specified by selecting side gear
thrust washer.
DI-00387
2. HYPOID DRIVEN GEAR BACKLASH
Using a dial gauge, check the backlash of hypoid
driven gear.
Hypoid driven gear backlash:
If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or re-
pair if necessary.
3. TOOTH CONTACT BETWEEN HYPOID
DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between hypoid driven
gear and drive pinion. <Ref. to DI-55, ASSEMBLY,
Rear Differential (VA-type).>
4. COMPANION FLANGE
1) If rust or dirt is attached to the companion flange,
remove them.
2) Set a dial gauge at a companion flange surface
(mating surface of propeller shaft and companion
flange), and then measure the companion flange
runout.
DI-70
0.05 — 0.15 mm (0.0020 — 0.0059 in)
0.10 — 0.15 mm (0.0039 — 0.0059 in)
DI-00240
DI-00099