2001 Subaru Outback Base, StandardFACTORY OEM SERVICE PROCEDURE

Front Differential: Installation

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 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 To Case
    G02876012Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the O-rings from left and right side retainer.
  3. Using ST, install the side retainers. < Ref. to REMOVAL , Front Differential.
    1. ST 499787000 WRENCH ASSY
  4. Install the lock plate.
    1. Tightening torque:  25 N.m (2.5 kgf-m, 18.1 ft-lb)
    Fig 2: Installing Lock Plate
    G02876013Courtesy of SUBARU OF AMERICA, INC.
  5. Install the new seal pipe to the torque converter clutch case.
    Fig 3: Installing New Seal Pipe To Torque Converter Clutch Case
    G02876014Courtesy of SUBARU OF AMERICA, INC.
  6. Install the torque converter clutch case to transmission case. < Ref. to INSTALLATION , Torque Converter Clutch Case.>
  7. Install air breather hose.
  8. Insert inhibitor switch and transmission connector into stay.
    Fig 4: Inserting Inhibitor Switch & Transmission Connector Into Stay
    G02876015Courtesy of SUBARU OF AMERICA, INC.
  9. Install oil cooler pipes. < Ref. to INSTALLATION , ATF Cooler Pipe and Hose.>
  10. Install the oil charger pipe with O-ring < Ref. to INSTALLATION , Oil Charger Pipe.>
  11. Insert the input shaft while turning lightly by hand. At this time, not to damage the bushing.
    1. Normal protrusion A:  50-55 mm (1.97-2.17 in)
    Fig 5: Inserting Input Shaft
    G02876016Courtesy of SUBARU OF AMERICA, INC.
  12. Install the torque converter clutch assembly.

    < Ref. to INSTALLATION , Torque Converter Clutch Assembly.>

  13. Install the transmission assembly to the vehicle. < Ref. to INSTALLATION , Automatic Transmission Assembly.>
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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.