Differential Case Assembly

2016 Subaru Legacy 2.5iSECTION Differential Case Assembly
WARNING: This page is about a different variant/trim than selected.
  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 Differential Bevel Gear Pinions, Differential Case (LH) And Pinion Shaft
    G10313931Courtesy 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) And Hypoid Driven Gear
    G06654725Courtesy of SUBARU OF AMERICA, INC.
  5. Install the washer and differential bevel gear to the differential case (RH).
    Fig 5: Identifying Differential Bevel Gear And Washer
    G06654714Courtesy of SUBARU OF AMERICA, INC.
  6. Using the ST, install the hypoid driven gear by tightening the installation bolt.

    ST 18270KA020 SOCKET (E20)

    Fig 6: Installing Hypoid Driven Gear Mounting Bolt Using Socket E20 (ST 18270KA020)
    G06654712Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque:Β 

    20 N.m (2.0 kgf-m, 14.8 ft-lb)Β 

  7. While checking the tightening angle with the angle gauge, further tighten the hypoid driven gear mounting bolts.

    Tightening angle:Β 

    45°  ±2° 

  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 in place with a screwdriver covered with cloth, or a similar tool.

      Specification:Β 

      0.13 - 0.18 mm (0.0051 - 0.0071 in)Β 

      Fig 7: Measuring Gear Backlash Using Dial Gauge (ST2 498247100)
      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: Installing Taper Roller Bearings Using Bushing 1-2 Installer (ST1 499277100)
    G06654729Courtesy of SUBARU OF AMERICA, INC.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.