2009 Subaru Outback LimitedFACTORY 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: Attaching Straight Pin
    G06337361Courtesy of SUBARU OF AMERICA, INC.
  3. Install the washer and differential bevel gear to differential case (LH). Put the differential case (RH) on the case, and assemble two cases.
  4. Install the hypoid driven gear and secure by tightening the bolt.

    Tightening torque: 62 N.m (6.3 kgf-m, 45.7 ft-lb) 

    Fig 2: Installing Hypoid Driven Gear
    G06337362Courtesy of SUBARU OF AMERICA, INC.
  5. Measurement of backlash (Selection of washer)
    1. Install the SUBARU genuine axle shaft to differential case.

      Part No. 38415AA070 Axle 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 differential bevel pinion tooth between two differential bevel gear teeth.
      • Fix the differential bevel pinion gear in place with a screwdriver covered with cloth or similar tool when measuring.

      Standard: 

      0.13 - 0.18 mm (0.0051 - 0.0071 in) 

      Fig 3: Measuring Differential Backlash
      G05002724Courtesy of SUBARU OF AMERICA, INC.
    3. If the backlash is out of specification, select a washer from the table below.
      THICKNESS SPECIFICATIONS

      Washer
      Part No. 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 INSTALLER

    Fig 4: Installing Taper Roller Bearing Using ST 398487700 Installer
    G06337364Courtesy of SUBARU OF AMERICA, INC.
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.