Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Forester 1999-2004 Approved Subaru Forester 1999-2000 TRANSMISSION AND DIFFERENTIAL SECTION AWD System MSA5T0124A27738

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3-4   [K200]                                            DIAGNOSTICS
2. Rear Differential

2. Rear Differential
                  Symptom                                     Possible cause                                  Remedy
 1. Oil leakage                                (1) Worn, scratched, or incorrectly            Repair or replace.
                                               seated front or side oil seal. Scored,
                                               battered, or excessively worn sliding sur-
                                               face of companion flange.
                                               (2) Clogged or damaged air breather.           Clean, repair or replace.
                                               (3) Loose bolts on differential spindle or     Tighten bolts to specified torque.
                                               side retainer, or incorrectly fitted O-ring.   Replace O-ring.
                                               (4) Loose rear cover attaching bolts or        Tighten bolts to specified torque.
                                               damaged gasket.                                Replace gasket and apply liquid packing.
                                               (5) Loose oil filler or drain plug.            Retighten and apply liquid packing.
                                               (6) Wear, damage or incorrectly fitting for    Repair or replace.
                                               spindle, side retainer and oil seal.
 2. Seizure                                    (1) Insufficient backlash for hypoid gear.     Readjust or replace.
 Seized or damaged parts should be             (2) Excessive preload for side, rear, or       Readjust or replace.
 replaced, and also other parts should be      front bearing.
 thoroughly checked for any defect and
                                               (3) Insufficient or improper oil used.         Replace seized part and fill with speci-
 should be repaired or replaced as
                                                                                              fied oil to specified level.
 3. Damage                                     (1) Improper backlash for hypoid gear.         Replace.
 NOTE:                                         (2) Insufficient or excessive preload for      Readjust or replace.
 Damaged parts should be replaced, and         side, rear, or front bearing.
 also other parts should be thoroughly         (3) Excessive backlash for differential        Replace gear or thrust washer.
 checked for any defect and should be          gear.
 repaired or replaced as required.
                                               (4) Loose bolts and nuts such as crown         Retighten.
                                               gear bolt.
                                               (5) Damage due to overloading.                 Replace.
 4. Noises when starting or shifting           (1) Excessive backlash for hypoid gear.        Readjust.
 gears                                         (2) Excessive backlash for differential        Replace gear or thrust washer.
 NOTE:                                         gear.
 Noises may be caused by differential          (3) Insufficient preload for front or rear     Readjust.
 assembly, universal joint, wheel bearing,     bearing.
 etc. Find out what is actually making
                                               (4) Loose drive pinion nut.                    Tighten to specified torque.
 noise before disassembly.
                                               (5) Loose bolts and nuts such as side          Tighten to specified torque.
                                               bearing retainer attaching bolt.
 5. Noises when cornering                      (1) Damaged differential gear.                 Replace.
                                               (2) Excessive wear or damage of thrust         Replace.
                                               (3) Broken pinion mate shaft.                  Replace.
                                               (4) Seized or damaged side bearing.            Replace.
 6. Gear noises                                (1) Improper tooth contact of hypoid           Readjust or replace hypoid gear set.
 NOTE:                                         gear.
 Since noises from engine, muffler,            (2) Improper backlash for hypoid gear.         Readjust.
 transmission, propeller shaft, wheel
                                               (3) Scored or chipped teeth of hypoid          Replace hypoid gear set.
 bearings, tires, and body are sometimes
 mistaken for noises from differential
 assembly, be careful in checking them.        (4) Seized hypoid gear.                        Replace hypoid gear set.
 Inspection methods to locate noises           (5) Improper preload for front or rear         Readjust.
 include coasting, accelerating, cruising,     bearings.
 and jacking-up all four wheels. Perform       (6) Seized, scored, or chipped front or        Replace.
 these inspections according to condition      rear bearing.
 of trouble. When listening to noises, shift
 gears into four wheel drive and fourth        (7) Seized, scored, or chipped side bear- Replace.
 speed position, trying to pick up only dif-   ing.
 ferential noise.                              (8) Vibrating differential carrier.            Replace.




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