2001 Subaru Outback Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Front Differential: Installation

  1. Install the differential assembly to the case, paying special attention not to damage the inside of the case (particularly, the differential side retainer contact surface).
    Fig 1: Installing Differential Assembly
    G02053256
  2. Install the circlip to the axle shaft, insert the shaft into the differential assembly, and tap it into position with a plastic hammer.
    CAUTION:
    • If no play is felt, check whether the shaft is fully inserted. If shaft insertion is correct, replace the axle shaft.
    • Be sure to use a new circlip.

    Thrust play: 

    1. 0.3 - 0.5 mm (0.012 - 0.020 in)
  3. Wrap vinyl tape around the splined portion of the axle shaft.
    Fig 2: Wrapping Splined Portion Of Axle Shaft With Vinyl Tape
    G02053257
  4. Install the oil seal and outer race (taper roller bearing) to the differential side retainer. Then screw in the retainer and the O-ring after coating the threads with oil.
    CAUTION:
    • Pay attention not to damage the oil seal lips.
    • Do not confuse the RH and LH oil seals.
    • Keep the O-ring removed from the retainer.
  5. Using ST, install the side retainers. See ADJUSTMENT  .

    ST 499787000 WRENCH ASSY

  6. Install the lock plate.

    Tightening torque: 

    1. 25 N.m (2.5 kgf-m, 18.1 ft-lb)
    Fig 3: Installing Side Bearing Retainers
    G02053258
  7. Install the seal pipe to the torque converter clutch case.
    CAUTION: Be sure to use a new seal pipe.
Factory Service Tools

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When to See a Mechanic

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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