2001 Subaru Outback Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Differential Case Assembly

WARNING: This page is about a different car, the 2003 Subaru Outback, 2003 Subaru Legacy, and 2003 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH).

    Insert the pinion shaft.

  2. Install straight pin from reverse direction.
    Fig 1: Installing Straight Pin From Reverse Direction
    G02876025Courtesy of SUBARU OF AMERICA, INC.
  3. Install the washer and differential bevel gear to the differential case (LH). Then put the case over the differential case (RH), and connect both cases.
  4. Install the crown gear and secure by tightening the bolt.
    1. Standard tightening torque:  62 N.m (6.3 kgf-m, 45.6 ft-lb)
    Fig 2: Installing Crown Gear
    G02876026Courtesy of SUBARU OF AMERICA, INC.
  5. Measurement of backlash (Selection of washer)
    1. Measure the gear backlash with ST1 and ST2, and insert ST2 through the access window of the case.
      1. ST1 498247001 MAGNET BASE
      2. ST2 498247100 DIAL GAUGE
      NOTE:
      • Measure the backlash by applying a pinion tooth between two bevel gear teeth.
      • Fix bevel pinion gear in place with a screwdriver or similar tool when measuring.
      1. Standard value:  0.13-0.18 mm (0.0051-0.0071 in)
      Fig 3: Measuring Gear Backlash
      G02876027Courtesy of SUBARU OF AMERICA, INC.
    2. If backlash is not as specified, select a washer from the table below.
      WASHER

      Part No. Thickness mm (in)
      803038021 0.95 (0.037)
      803038022 1.00 (0.039)
      803038023 1.05(0.041)
    3. Using ST, install taper roller bearing.
      1. ST 398437700 DRIFT
      Fig 4: Installing Taper Roller Bearing
      G02876028Courtesy of SUBARU OF AMERICA, INC.
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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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