2012 Subaru Outback Base, Automatic CVT TransFACTORY OEM SERVICE PROCEDURE

Differential Case ASSY

  1. Install the washer and differential bevel gear into differential case (LH).
    Fig 1: Identifying Washer And Differential Bevel Gear
    G06654722Courtesy of SUBARU OF AMERICA, INC.
  2. Install the differential bevel gear pinions into differential case (LH) and install the pinion shaft.
    Fig 2: Identifying Pinion Shaft, Differential Bevel Gear And Differential Bevel Pinion
    G07913669Courtesy of SUBARU OF AMERICA, INC.
  3. Install the straight pin.
    Fig 3: Installing Straight Pin
    G06654724Courtesy of SUBARU OF AMERICA, INC.
  4. Install the differential case (RH) to hypoid driven gear and secure with vise.
    Fig 4: Identifying Differential Case (RH)
    G06654725Courtesy of SUBARU OF AMERICA, INC.
  5. Install the washer and differential bevel gear to the differential case (RH).
    Fig 5: Identifying Washer And Differential Bevel Gear
    G06654714Courtesy of SUBARU OF AMERICA, INC.
  6. Using the ST, install the hypoid driven gear by tightening the installation bolt.

    ST 18270KA020 SOCKET (E20)

    Tightening torque: 

    20 N.m (2.0 kgf-m, 14.8 ft-lb) 

    Fig 6: Identifying Hypoid Driven Gear With Socket
    G06654712Courtesy of SUBARU OF AMERICA, INC.
  7. While checking the tightening angle with the ST, further tighten the hypoid driven gear mounting bolts.

    Tightening angle: 

    28°±2° 

    ST 18554AA000 ANGLE GAUGE

  8. 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 through the window of differential 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.
      • When measuring, fix the differential bevel pinion gear in place with a screwdriver covered with cloth, or a similar tool.

      Specification: 

      0.13 - 0.18 mm (0.0051 - 0.0071 in) 

      Fig 7: Identifying Differential Bevel Pinion Gear With Bushing 1-2 Installer And Seat
      G06654728Courtesy of SUBARU OF AMERICA, INC.
    3. If the backlash is not within specification, select a washer from the table below and replace.
      Washer
      Part No. Thickness mm (in)
      803038021 0.95 (0.037)
      803038022 1.00 (0.039)
      803038023 1.05 (0.041)
  9. Using the ST, install the left and right taper roller bearings.

    ST1 499277100 BUSHING 1-2 INSTALLER

    ST2 398497701 SEAT

    Fig 8: Identifying Left And Right Taper Roller Bearings With Bushing 1-2 Installer And Seat
    G06654729Courtesy 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.

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