Subaru Legacy BN/BS (2015-2019) Service Manual: Adjustment

Subaru Legacy BN/BS (2015-2019) Service Manual / Manual transmission and differential(6mt) / Front differential assembly / Adjustment

1. DIFFERENTIAL BEVEL PINION GEAR BACKLASH

1. Disassemble the front differential assembly. Front Differential Assembly > DISASSEMBLY

2. Select the adjusting washer from the table and install.

Adjusting washer
Part No.	Thickness mm (in)
803038021	0.925 — 0.950 (0.0364 — 0.0374)
803038022	0.975 — 1.000 (0.0384 — 0.0394)
803038023	1.025 — 1.050 (0.0404 — 0.0413)

3. Adjust until the standard value is obtained.

Backlash:

Standard

0.13 — 0.18 mm (0.0051 — 0.0071 in)

2. HYPOID DRIVEN GEAR BACKLASH

Adjust the backlash by turning the differential side retainers on the left and right side.

ST 18630AA010

WRENCH COMPL RETAINER

NOTE:

Each time the differential side retainer rotates by one notch (A), the backlash changes by 0.05 mm (0.0020 in).

3. TOOTH CONTACT OF HYPOID DRIVEN GEAR

1. Adjust until correct teeth contact is obtained.

2. Check tooth contact, and perform the adjustment as follows.

• Correct tooth contact

Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.)

(A)	Toe side
(B)	Heel side

• Face contact

Check item: Backlash is too large.

Contact pattern

Corrective action: Tighten the differential side retainer to move the hypoid driven gear closer to the drive pinion shaft.

• Flank contact

Check item: Backlash is too small.

Contact pattern

Corrective action: Loosen the differential side retainer to move the hypoid driven gear away from the drive pinion shaft.

• Toe contact (inside contact)

Check item: Teeth contact area is too small.

Contact pattern

Corrective action: Increase the thickness of drive pinion shim and tighten the differential side retainer to move the hypoid driven gear closer to the drive pinion shaft according to the procedure for bringing drive pinion shaft away from hypoid driven gear.

• Heel contact (outside end contact)

Check item: Teeth contact area is too small.

Contact pattern

Corrective action: Reduce thickness of the drive pinion shim according to the procedures for moving the drive pinion shaft closer to driven gear. Also loosen the differential side retainer to move the hypoid driven gear away from the drive pinion shaft.

Removal

1. Remove the manual transmission assembly from the vehicle. Manual Transmission Assembly > REMOVAL2. Remove the transfer case together with the extension case assembly. Transfer Case and Extension ...

Installation

1. Install the differential side retainers using ST.ST 18630AA010WRENCH COMPL RETAINER2. Install the taper roller bearing outer race to the transmission case.3. Install the front differential assem ...

Other materials:

Inspection
1. Check the motor operation when battery voltage is applied between the connector terminals.• LH sideTerminal No.Inspection conditionsStandard6 (+) — 3 (−)Apply battery voltage between terminals.Increase3 (+) — 6 (−)Apply battery voltage between terminals.Decrease• RH si ...