2004 Subaru Baja 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 To Case
    G00924214Courtesy of SUBARU OF AMERICA, INC.
  2. Install the new circlip to the axle shaft, insert the shaft into the differential assembly, and tap it into position with a plastic hammer. (Except TURBO model)
    NOTE: If no play is felt, check whether the shaft is fully inserted. If shaft insertion is correct, replace the axle shaft.
    1. Thrust play: 0.3 - 0.5 mm (0.012 - 0.020 in) 
  3. Wrap vinyl tape around the splined portion of the axle shaft. (Except TURBO model)
  4. Install the O-rings from left and right side retainer.
  5. Using ST, install the side retainers. Refer to REMOVAL .

    ST 499787000 WRENCH ASSY

  6. Adjust the front differential backlash. Refer to ADJUSTMENT .
  7. Install the lock plate.
    1. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb) 
    Fig 2: Installing Lock Plate
    G00924215Courtesy of SUBARU OF AMERICA, INC.
  8. Install a new seal pipe to the torque converter clutch case.
    Fig 3: Installing Seal Pipe To Torque Converter Clutch Case
    G00924216Courtesy of SUBARU OF AMERICA, INC.
  9. Install the torque converter clutch case to transmission case. Refer to INSTALLATION .
  10. Insert the inhibitor switch and transmission connector into stay.
    Fig 4: Inserting Inhibitor Switch & Transmission Connector Into Stay
    G00924217Courtesy of SUBARU OF AMERICA, INC.
  11. Install the oil cooler pipes. Refer to INSTALLATION .
  12. Install the oil charger pipe with O-ring. Refer to INSTALLATION .
  13. Insert the input shaft while turning it lightly by hand and verify the protrusion amount.
    1. Normal protrusion A: 50 - 55 mm (1.97 - 2.17 in) 
    Fig 5: Inserting Input Shaft
    G00924218Courtesy of SUBARU OF AMERICA, INC.
  14. Install the torque converter clutch assembly.

    Refer to INSTALLATION .

  15. Install the transmission assembly to the vehicle. Refer to INSTALLATION .
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.