Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Legacy 1995-1999 Approved Subaru Legacy 1996 1996 Service Manual TRANSMISSION AND DIFFERENTIAL SECTION MANUAL TRANSMISSION AND DIFFERENTIAL MSA5TCD96L6084

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  SERVICE PROCEDURE                                               3-1
                                                   9. Front Differential


          9. Front Differential
          A: DISASSEMBLY
          1) Remove right and left snap rings k from differential,
                                                1
          and then remove two axle drive shafts k .
                                                 2
          NOTE:
          During reassembly, reinstall each axle drive shaft in the
          same place from which it was removed.
          2) Loosen twelve bolts k and remove hypoid drive gear
                                  3
          k.
           4




G3M0666


          3) Drive out straight pin k from differential assembly
                                     5
          toward hypoid driven gear.
          ST    899904100 REMOVER




G3M0667


          4) Pull out pinion shaft k , and remove differential bevel
                                   6
          pinion k and gear k and washer k .
                 7            8              9




G3M0666



                65
3-1                        SERVICE PROCEDURE
9. Front Differential


                                   5) Remove roller bearing using ST.
                                   ST   399527700 PULLER SET




                        G3M0668


                                   B: ASSEMBLY
                                   1) Install bevel gear and bevel pinion together with
                                   washers, and insert pinion shaft k .
                                                                    1
                                   NOTE:
                                   Face the chamfered side of washer toward gear.




                        B3M0099A


                                   2) Measure backlash between bevel gear and pinion. If it
                                   is not within specifications, install a suitable washer to
                                   adjust it.
                                   Standard backlash:
                                       0.13 -- 0.18 mm (0.0051 -- 0.0071 in)
                                   ST1 498247001 MAGNET BASE
                                   ST2 498247100 DIAL GAUGE
                                   NOTE:
                                   Be sure the pinion gear tooth contacts adjacent gear teeth
                        G3M0670
                                   during measurement.
                                                          Washer (38.1 x 50 x t)
                                               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)




                                         66
  SERVICE PROCEDURE                                                 3-1
                                                     9. Front Differential


          3) Align pinion shaft and differential case at their holes,
          and drive straight pin k into holes from the hypoid driven
                                  5
          gear side, using ST.
          ST     899904100 REMOVER
          NOTE:
          Lock straight pin after installing.




G3M0666


          4) Install roller bearing (40 x 80 x 19.75) to differential
          case.
          NOTE:
          Be careful because roller bearing outer races are used as
          a set.
          ST1 499277100 BUSH 1-2 INSTALLER
          ST2 398497701 ADAPTER

G3M0671


          5) Install hypoid driven gear k to differential case k using
                                        4                      10
          twelve bolts k .
                        3
          Tightening torque:
             62

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