Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Forester 1999-2004 Approved Subaru Forester 2004 4 - Chassis Differentials General Diagnostic Table
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GENERAL DIAGNOSTIC TABLE
DIFFERENTIALS
8. General Diagnostic Table
A: INSPECTION
Symptom or trouble Possible cause Remedy
1. Oil leakage (1) Worn, scratched, or incorrectly seated Repair or replace.
front or side oil seal. Scored, battered, or
excessively worn sliding surface of com-
panion flange.
(2) Clogged or damaged air breather. Clean, repair or replace.
(3) Loose bolts on side retainer, or incor- Tighten the bolts to specified torque.
rectly fitted O-ring. Replace the O-ring.
(4) Loose rear cover attaching bolts or Tighten the bolts to specified torque.
damaged gasket. Replace the gasket and apply Liquid gas-
ket.
(5) Loose oil filler or drain plug. Retighten and apply Liquid gasket.
(6) Wear, damage or incorrectly fitting for Repair or replace.
side retainer and oil seal.
2. Seizure (1) Insufficient backlash for hypoid gear. Readjust or replace.
NOTE: (2) Excessive preload for side, rear, or Readjust or replace.
Seized or damaged parts should be re- front bearing.
placed, and also other parts should be
(3) Insufficient or improper oil used. Replace the seized part and fill with spec-
thoroughly checked for any defect and
ified oil to specified level.
should be repaired or replaced as re-
quired.
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 the gear or thrust washer.
checked for any defect and should be re-
gear.
paired or replaced as required.
(4) Loose bolts and nuts such as hypoid Retighten.
driven 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 the gear or thrust washer.
NOTE: gear.
Noises may be caused by differential as-
(3) Insufficient preload for front or rear Readjust.
sembly, universal joint, wheel bearing,
bearing.
etc. Find out what is actually making noise
before disassembly. (4) Loose drive pinion nut. Tighten to specified torque.
(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.
washer.
(3) Broken pinion mate shaft. Replace.
(4) Seized or damaged side bearing. Replace.
DI-40
GENERAL DIAGNOSTIC TABLE
DIFFERENTIALS
Symptom or trouble Possible cause Remedy
6. Gear noises (1) Improper tooth contact of hypoid gear. Readjust or replace the hypoid gear set.
NOTE: (2) Improper backlash for hypoid gear. Readjust.
Since noises from engine, muffler, trans-
(3) Scored or chipped teeth of hypoid Replace the hypoid gear set.
mission, propeller shaft, wheel bearings,
gear.
tires, and body are sometimes mistaken
for noises from differential assembly, be (4) Seized hypoid gear. Replace the hypoid gear set.
careful in checking them. Inspection (5) Improper preload for front or rear Readjust.
methods to locate noises include coast- bearings.
ing, accelerating, cruising, and jacking-up (6) Seized, scored, or chipped front or Replace.
all four wheels. Perform these inspections rear bearing.
according to condition of trouble. When (7) Seized, scored, or chipped side bear- Replace.
listening to noises, shift gears into four ing.
wheel drive and fourth speed position, try-
(8) Vibrating differential carrier. Replace.
ing to pick up only differential noise.
DI-41
GENERAL DIAGNOSTIC TABLE
DIFFERENTIALS
DI-42
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