2006 Subaru Outback RFACTORY OEM SERVICE PROCEDURE

Differential Case Assembly

  1. Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH). Insert the pinion shaft.
  2. Attach the straight pin in the reverse direction.
    Fig 1: Identifying Differential Case
    G05022382
  3. Install the washer and differential bevel gear to differential case (LH). Put the differential case (RH) on the case, and then assemble the two cases.
  4. Install the hypoid driven gear and secure by tightening the bolt.

    Tightening torque: 

    62 N.m (6.3 kgf-m, 45.6 ft-lb) 

    Fig 2: Identifying Hypoid Driven Gear And Differential Case
    G05022383
  5. Measurement of backlash (Selection of washer)
    1. Install the SUBARU genuine axle shaft to differential case.

      Part No. 38415AA070AXLE SHAFT

    2. Measure the gear backlash using ST1 and ST2, and then insert the ST2 though the access window of case.

      ST1 498247001 MAGNET BASE

      ST2 498247100 DIAL GAUGE

      NOTE:
      • Measure the backlash by applying a pinion tooth between two bevel gear teeth.
      • Fix the bevel pinion gear in place with a screwdriver or similar tool when measuring.

      Standard value: 0.13 - 0.18 mm (0.0051 - 0.0071 in) 

      Fig 3: Measuring Gear Backlash
      G05002724
    3. If the backlash is not within specification, select a washer from the table below.
      THICKNESS CHART

      Washer
      Part number Thickness mm (in)
      803038021 0.95 (0.037)
      803038022 1.00 (0.039)
      803038023 1.05(0.041)
  6. Using the ST, install the taper roller bearing.

    ST 398487700 DRIFT

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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.