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2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX

1. DI 9 6 Gasket 7 Oil filler plug 8 Oil drain plug 9 Rear cover Tightening torque N m kgf m ft Ib T1 25 2 5 18 1 T2 25 2 5 18 1 T3 34 3 5 25 3 T4 62 6 3 45 6 T5 188 19 2 139 Differentials 4 REAR DIFFERENTIAL MOUNTING SYSTEM S303001A0504 GENERAL DESCRIPTION S3M0231A Differential front member Plate Crossmember Rear bushing Differential mount lower bracket Non Turbo model Differential mount lower bracket Turbo model Stopper Differential mount bracket Dynamic damper A 0 Mass damper Turbo model 1 Dynamic damper B Non Turbo model 12 Differential mount front cover 8 9 1 1 DI 10 Tightening torque N m kgf m ft lb T1 20 2 0 14 5 T2 32 3 3 23 9 T3 40 4 1 30 T4 64 6 5 47 0 T5 69 7 0 50 6 T6 69 7 0 50 6 7 88 9 0 65 T8 98 10 0 72 GENERAL DESCRIPTION Differentials S CAUTION S303001A03 e Wear working clothing including a cap protec tive goggles and protective shoes during opera tion e Remove contamination including dirt and corro sion before removal installation or disassembly e Keep the disassembled parts in order and pro tect them from dust or dirt e Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary removal installation disassembly and replace ment e Becareful not to burn yo
2. 38336AA190 1 688 mm 0 0665 in 38336AA080 1 700 mm 0 0669 in 38336AA200 1 713 mm 38336AA090 1 725 mm 38336AA210 1 738 mm 38336AA100 1 750 mm 38336AA220 1 763 mm 0 0694 in 0 0674 in 38336AA110 1 775 mm 0 0699 in 0 0679 in 0 0684 in 0 0689 in 32295AA200 0 150 mm 0 0059 in 32295AA210 0 175 mm 0 0069 in 32295AA220 0 200 mm 0 0079 in 32295AA230 0 225 mm 0 0089 in 32295AA240 0 250 mm 0 0098 in 32295AA250 0 275 mm 0 0108 in 0 925 0 950 mm 509135011 0 0364 0 0374 in 0 950 0 975 mm 0 0374 0 0384 in 0 975 1 000 mm 0 0384 0 0394 in 1 000 1 025 mm 0 0394 0 0404 in 1 025 1 050 mm 0 0404 0 0413 in Pinion height adjusting shim 803135012 Side gear thrust washer 803135013 803135014 803135015 DI 4 GENERAL DESCRIPTION Differentials e T type Part No Length or thickness 383695201 56 2 mm 2 213 in 383695202 56 4 mm 2 220 in 383695203 56 6 mm 2 228 in 383695204 56 8 mm 2 236 in Preload adjusting spacer 383695205 57 0 mm 2 244 in 383695206 57 2 mm 2 252 in 383705200 2 59 mm 0 1020 in 383715200 2 57 mm 0 1012 in 383725200 2 55 mm 0 1004 in 383735200 2 53 mm 0 0996 in 383745200 2 51 mm 0 0988 in 383755200 2 49 mm 0 0980 in 383765200 2 47 mm 0 0972 in Preload adjusting washer 383775200 2 45 mm 0 0965 in 3837
3. Adjusting direction of drive pinion Adjusting direction of crown gear This may cause chipping at toe ends G3M0098D This may cause chipping at heel ends G3M0098bE DI 39 Adjust as for flank contact G3M0098G Adjust as for face contact G3M0098F REAR DIFFERENTIAL FOR T TYPE Differentials 19 Install rear cover and tighten bolts to specified torque CAUTION Securely connect ground terminal of rear dif ferential temperature sensor Tightening torque 29 3 0 kgf m 21 7 ft lb G3M1050 E INSPECTION S303145A10 Wash all the disassembled parts clean and exam ine them for wear damage or other defects Repair or replace defective parts as necessary 1 Crown gear and drive pinion e f abnormal tooth contact is evident find out the cause and adjust to give correct tooth contact at assembly Replace the gear if excessively worn or incapable of adjustment e f crack score or seizure is evident replace as a set Slight damage of tooth can be corrected by oil stone or the like 2 Side gear and pinion mate gear e Replace if crack score or other defects are evi dent on tooth surface e Replace if thrust washer contacting surface is worn or seized Slight damage of the surface can be corrected by oil stone or the like 3 Bearing Replace if seizure peeling wear rust dragging during rotation abnormal noise or other defect is evident 4 Thrust washers of s
4. 4 Remove the oil drain plug and filler plug and drain the gear oil CAUTION Be careful not to burn your hands because gear oil becomes extremely hot after running B3 0136B A Filler plug B Drain plug 5 Tighten oil drain plug CAUTION e Apply fluid packing to drain plug in T type e VA type uses a new aluminum gasket Fluid packing THREE BOND 1105 or equivalent Tightening torque T type 49 0 N m 5 0 kgf m 36 2 ft Ib VA type 34 N m 3 5 kgf m 25 3 ft Ib 01 22 DIFFERENTIAL GEAR OIL 6 Fill differential carrier with gear oil to the upper plug level CAUTION Carefully refill oil while watching the level Excess or insufficient oil must be avoided Oil capacity 0 8 0 8 US qt 0 7 Imp qt 53 0527 A Filler plug B Drain plug 7 Install filler plug CAUTION e Apply fluid packing to drain plug in T type e VA type uses a new aluminum gasket Fluid packing THREE BOND 1105 or equivalent Tightening torque T type 49 0 N m 5 0 kgf m 36 2 ft Ib VA type 34 N m 3 5 kgf m 25 3 ft Ib 8 Connect oil temperature sensor connector 01 23 Differentials FRONT DIFFERENTIAL Differentials 3 Front Differential A NOTE 5303152 15 1 MODEL 5303152 1501 Refer to AUTOMATIC TRANSMISSION rate publication AUTOMATIC TRANSMISSION for Front Differential Pub No G0853ZE 2 MT MODEL 5303 152 1502 For front dif
5. Used for stopping rotaiotn of companion flange when loosening and tightening self lock nut Used for removing pinion pilot bearing and front bearing cone B3M1899 399780104 WEIGHT Used for installing front bearing cone pilot bearing companion flange B3M1900 899580100 INSTALLER Used for press fitting the front bearing cone pilot bearing B3M1901 899904100 STRAIGHT PIN REMOVER DI 13 Used for driving out differential pinion shaft lock pin Differentials ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION REMARKS B3M1930 B3M1902 399703600 498247001 PULLEY ASSY MAGENT BASE e Used for removing companion flange e Used for measuring backlash between side gear and pinion and hypoid gear e Used with DIAL GAUGE 498247100 B3M1903 B3M1904 498247100 398507704 DAIL GAUGE DI 14 e Used measurng backlash between side gear and pinion hypoid gear e Used with MAGNET BASE 498247001 Used for adjusting pinion height and preload ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION Differentials REMARKS B3M1905 398177700 INSTALLER e Used for installing rear bearing cone e For T type B3M1906 B3M1907 398457700 398477703 ATTACHMENT DRIFT2 e Used for removing side bearing retainer e For T type e Used forpress fitting the bearing race rear of differential
6. N 4 Release the parking brake 5 Lift the vehicle 6 Remove oil drain plug and drain gear oil B3M0136B A Drain plug B Filler plug 7 Install oil drain plug CAUTION e Apply fluid packing to drain plug in T type e VA type uses a new aluminum gasket Tightening torque T type 49 N m 5 0 kgf m 36 2 ft Ib VA type 34 N m 3 5 kgf m 25 3 ft Ib 8 Remove rear exhaust pipe and muffler 9 Remove propeller shaft from body Ref to DS 17 REMOVAL Propeller Shaft gt Differentials 10 Remove self locking nut while holding com panion flange with ST ST 498427200 FLANGE WRENCH S3M0031A 11 Extract companion flange using ST ST 399703600 PULLEY ASSY B3M1644B 12 Remove oil seal using ST ST 499705401 PULLER ASSY B3M1609B 13 Fit a new oil seal using ST ST 498447120 OIL SEAL INSTALLER G3M0037 14 Install companion flange DI 59 REAR DIFFERENTIAL FRONT OIL SEAL Differentials NOTE Use a plastic hammer to install companion flange 15 Tighten self locking nut within the specified torque range so that the turning resistance of com panion flange becomes the same as that before replacing oil seal ST 498427200 FLANGE WRENCH CAUTION Use a new self locking nut Tightening torque 181 4 N m 18 50 kgf m 133 8 ft lb S3M0031A 16 Install in the reverse order of removal 17 Fill differential carrier
7. e Tooth contact of crown gear and pinion and backlash e Runout of crown gear at its back surface e Turning resistance of drive pinion 1 Set ST on vise and install the differential assembly to ST ST 398217700 ATTACHMENT G3M0060 2 Drain gear oil by removing plug 3 Remove rear cover by loosening retaining bolts S3M0506 4 Replace air breather cap NOTE Do not attempt to replace the air breather cap unless necessary A B A Air breather cap B Rear cover S3M0507A 5 Remove right and left lock plates G3M0063 DI 44 REAR DIFFERENTIAL FOR VA TYPE 6 Remove right and left holders with ST ST 399780111 WRENCH G3M0064 7 Pull out differential assembly from differential case CAUTION Be careful not to hit the teeth against the case G3M0065 8 Remove bearing race from right and left holders with ST1 and ST2 ST1 499705401 PULLER ASSY ST2 499705404 OUTER RACE PULLER SEAT S3M0508A A Bearing race B Holder Differentials 9 Remove oil seal from right and left holders with screwdriver CAUTION Perform this operation only when changing oil seal B3M0132 10 Extract bearing cone with ST1 and ST2 CAUTION Do not attempt to disassemble the parts unless necessary NOTE e Set Puller so that its claws catch the edge of the bearing cone e Nev
8. 1417 383675200 3 63 0 1429 383685200 3 66 0 1441 4 Install the selected pinion height adjusting shim drive pinion and press the rear bearing cone into position with ST ST 398177700 INSTALLER S3M0519A DI 33 REAR DIFFERENTIAL FOR T TYPE Differentials 5 Insert drive pinion into differential carrier install the previously selected bearing preload adjusting spacer and washer LY Ne B3M0560B Drive pinion Bearing adjusting spacer Washer Differential carrier Sous 6 Press fit front bearing cone into case with ST1 ST2 and ST3 ST1 398507703 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER G3M0085 7 Insert spacer then press fit pilot bearing with ST1 and ST2 ST1 399780104 WEIGHT ST2 899580100 INSTALLER S3M0520A 8 Fit a new oil seal with ST NOTE e Press fit until end of oil seal is 1 mm 0 04 in inward from end of carrier e Apply grease between the oil seal lips ST 498447120 INSTALLER G3M0087 9 Press fit companion flange with ST1 and ST2 CAUTION Be careful not to damage bearing ST1 899874100 INSTALLER ST2 399780104 WEIGHT S3M0521A 10 Install self locking nut Then tighten it with ST ST 498427200 FLANGE WRENCH Tightening torque 181 N m 18 5 kgf m 134 ft lb G3
9. Rear Differential Side Oil 61 8 Rear Differential Member 66 9 General Diagnostic Table eee eee eee eee GENERAL DESCRIPTION Differentials 1 General Description s A SPECIFICATIONS Non Turbo E E AT Europe xcept Europe MT VA type T type with LSD HP with oil tem perature sensor Gear Hypoid gear Gear ratio 4 111 37 9 4 444 40 9 Oil capacity 0 8 L 0 8 US qt 0 7 Imp qt Rear differential gear oil GL 5 Rear differential type XH CF e Identification When replacing a rear differential assembly select the correct one according to the following table CAUTION Using the different rear differential assembly causes the drive line and tires to drag or emit abnormal noise when AWD is selected ER S3M0613 DI 2 GENERAL DESCRIPTION Differentials e Rear differential gear oil Recommended oil CAUTION Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands ITEM Rear differential gear oil API Classification SAE Viscosity No and Application Temperature C 30 26 15 5 0 15 25 30 22 15 5 23 32 59 77 86 H3M1272A 1 SERVICE DATA sonan 19 6 28 4 2 0 2 9 4 4 6 4 12 7 32 4 1 3 3 8 2 9 7 3 Used bearing 8 34 16 67 0 85 1 7 1 87 3 75 0 10 0 2
10. ST ST 398467700 DRIFT B A S3M0514A A Pinion bearing B Front bearing C Rear bearing cup DI 30 REAR DIFFERENTIAL FOR T TYPE Differentials 18 When replacing bearings tap front bearing cup and rear bearing cup in this order out of case by using a brass bar S3M0515A A 2 cutouts along diagonal lines B Tap alternately with brass bar D ASSEMBLY 5303145402 1 Precautions for assembling e Assemble in the reverse order of disassembling e Check and adjust each part during assembly e For correct installation keep the shims and washers in order e Thoroughly clean the surfaces on which the shims washers and bearings are to be installed e Apply gear oil when installing the bearings and thrust washers e Be careful not to mix up the right and left hand races of the bearings e Replace the oil seal with new one at every dis assembly Apply chassis grease between the lips when installing the oil seal G3M0079 2 Adjusting preload for front and rear bearings Adjust the bearing preload with spacer and washer between front and rear bearings Pinion height adjusting washer are not affected by this adjust ment The adjustment must be carried out without oil seal inserted 1 Press rear bearing race into differential car rier with ST1 and ST2 ST1 398477701 HANDLE ST2 398477703 DRIFT2 G3M1037 2 Insert ST1 into carrier with pinion he
11. mm Result Thickness 0 2 mm Therefore use the 32295AA220 Pinion height adjusting shim Thickness mm in 0 150 0 0059 Part No 32295AA200 32295AA210 0 175 0 0069 32295AA220 0 200 0 0079 32295AA230 0 225 0 0089 32295AA240 0 250 0 0098 32295AA250 0 275 0 0108 4 Install the selected pinion height adjusting shim drive pinion and press the rear bearing cone into position with ST ST 498175500 INSTALLER S3M0519A 5 Insert drive pinion into differential carrier install the previously selected bearing preload adjusting spacer and washer A SS H3M1666A Drive pinion Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier SOBs 6 Press fit front bearing cone into carrier with ST1 ST2 and ST3 ST1 32285AA000 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER ST3 ST ST2 G3M0085 7 Insert spacer then press fit pilot bearing with ST1 and ST2 ST1 399780104 WEIGHT ST2 899580100 INSTALLER S3M0520A DI 50 REAR DIFFERENTIAL FOR VA TYPE Differentials 8 Fit a new oil seal with ST 11 Assembling differential case NOTE Install side gears and pinion mate gears with their Press fit until end of oil seal is 1 mm 0 04 in thrust washers and pinion mate shaft into differen inward from end of carrier tial case e Apply grease between the oil seal li
12. the crown gear to drive pinion backlash Set magnet base on differential car rier Align contact point of dial gauge with tooth face of crown gear and move crown gear while holding drive pinion still Read value indicated on dial gauge NOTE If measured backlash is not within specified range repeat procedures for pinion crown gear set back lash adjustment and differential side bearing pre load adjustment Backlash 0 10 0 15 mm 0 0039 0 0059 in DI 53 REAR DIFFERENTIAL FOR VA TYPE Differentials 15 Draw a matching mark on both differential car rier and holder Remove holder one side at a time Replace in the original position after inserting an O ring and applying grease to threaded portion S3M0524A A Matching mark B Holder 16 Tighten bolt of lock plate to specified torque Tightening torque 25 2 5 kgf m 18 1 ft lb G3M0063 17 Re check crown gear to pinion backlash Backlash 0 10 0 15 mm 0 0039 0 0059 in 18 Check the crown gear runout on its back surface and make sure pinion and crown gear rotate smoothly Limit of runout 0 05 mm 0 0020 in S3M0525 19 Checking and adjusting tooth contact of crown gear 1 Apply an even coat of red lead on both sides of three or four teeth on the crown gear Check the contact pattern after rotating crown gear several revolutions back and forth until a defi
13. 0 0 0039 0 0079 0 05 0 15 0 0020 0 0059 Side bearing standard width mm in 20 00 0 7874 0 10 0 20 0 0039 0 0079 0 10 0 15 0 0039 0 0059 Crown gear runout on its back surface mm in Less than 0 05 0 0020 Front and rear bearing preload at companion New bearing flange bolt hole kgf Ib Side gear backlash mm Crown gear to drive pinion backlash mm DI 3 GENERAL DESCRIPTION Differentials 2 ADJUSTING PARTS coz e VA type Part No Length or thickness 32288AA040 52 3 mm 2 059 in 32288AA050 52 5 mm 2 067 in 31454AA100 52 6 mm 2 071 in 32288AA060 52 7 mm 2 075 in Preload adjusting spacer 32288AA070 52 9 mm 2 083 in 31454AA120 53 0 mm 2 087 in 32288AA080 53 1 mm 2 091 in 32288AA090 53 3 mm 2 098 in 38336AA000 1 500 mm 0 0591 in 38336AA120 1 513 mm 0 0596 in 38336AA010 1 525 mm 0 0600 in 38336AA130 1 538 mm 0 0606 in 38336AA020 1 550 mm 0 0610 in 38336AA140 1 563 mm 0 0615 in 38336AA030 1 575 mm 0 0620 in 38336AA150 1 588 mm 0 0625 in 38336AA040 1 600 mm 0 0630 in 38336AA160 1 613 mm 0 0635 in 38336AA050 1 625 mm 0 0640 in Preload adjusting washer 38336AA170 1 638 mm 0 0645 in 38336AA060 1 650 mm 0 0650 in 38336AA180 1 663 mm 0 0655 in 38336AA070 1 675 mm 0 0659 in
14. 0 0039 0 0059 in If crown gear backlash is not within the specification adjust the side bearing preload or repair if necessary G3M1047 DI 57 REAR DIFFERENTIAL FOR VA TYPE Differentials 3 CROWN GEAR RUNOUT sun Using a dial gauge check the crown gear runout Crown gear runout Less than 0 05 mm 0 0020 in If the crown gear runout exceeds 0 05 mm 0 0020 in replace the crown gear S3M0525 4 TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION o Inspect tooth contact between crown gear and drive pinion Ref to DI 47 ASSEMBLY Rear Differential for VA type F ADJ USTMENT 303151A01 1 SIDE GEAR BACKLASH Adjust side gear backlash Ref to 01 47 ASSEMBLY Rear Differential for VA type 2 CROWN GEAR BACKLASH Adjust crown gear backlash Ref to 01 47 ASSEMBLY Rear Differential for VA type 3 TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION ann Adjust the tooth contact between crown gear and drive pinion gear Ref to DI 47 ASSEMBLY Rear Differential for VA type DI 58 REAR DIFFERENTIAL FRONT OIL SEAL 6 Rear Differential Front Oil Seal A INSPECTION 5303 139 10 Check front oil seal portion for oil leakage if any leak is found replace the oil seal and inspect pro peller shaft B REPLACEMENT 1 Set vehicle on a lift 2 Disconnect ground cable from battery 3 Move select lever or gear shift lever to
15. 2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION FRONT SUSPENSION REAR SUSPENSION WHEEL ANDTIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles This manual includes the procedures for maintenance disassembling reassem bling inspection and adjustment of com ponents and diagnostics for guidance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genu ine parts TRANSFER CASE DRIVE SHAFT SYSTEM ABS BRAKE PARKING BRAKE POWER ASSISTED SYSTEM POWER STEERING ABS DIAGNOSTICS All information illustration and specifica tions contained in this manual are based on the latest product information avail able at the time of publication approval FUJI HEAVY INDUSTRIES LTD G8050GE5 DIFFERENTIALS Di Te General Descripilofi 2 Differential Gear OU Front Differential ote etos 24 4 Rear Differential for 4 5 Rear Differential for VA type 6 Rear Differential Front Oil Seal 7
16. 383475204 0 40 mm 0 0157 in 383475205 DI 6 0 30 mm 0 0118 in 0 50 mm 0 0197 in GENERAL DESCRIPTION Differentials B S303001A05 1 REAR DIFFERENTIAL FOR T TYPE WITHOUT LSD us B3M0130C Pinion crown gear set Pinion height adjusting washer Rear bearing Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier Front bearing Spacer Pilot bearing Front oil seal Companion flange Self locking nut KKK GEGEE T 710 ONO KM kO e o 3 Side bearing 4 O ring 5 Side bearing retainer shim 6 Side bearing retainer 7 Side oil seal 8 Side gear thrust washer 9 Side gear 0 Pinion mate gear 1 Pinion mate gear washer 2 Pinion shaft lock pin 3 Circlip 4 Pinion mate shaft 5 1 1 1 1 1 1 1 2 2 2 2 2 25 Air breather DI 7 26 Stud bolt 27 Oil filler plug 28 Oil drain plug 29 Rear cover 30 Differential case Tightening torque N m kgf m ft Ib T1 10 3 1 05 7 6 T2 29 4 3 00 21 7 T3 49 0 5 0 36 2 T4 103 0 10 50 75 9 T5 181 4 18 50 133 8 Differentials 2 REAR DIFFERENTIAL FOR T TYPE WITH LSD S303001A0502 GENERAL DESCRIPTION 21 J 23 AS S3M0643A Pinion crown gear set Pinion height adjusting shim Rear bearing Bearing preload adjustin
17. 383745200 2 51 0 0988 383755200 2 49 0 0980 Preload adjusting 383765200 2 47 0 0972 Thickness mm 2 59 0 1020 2 57 0 1012 2 55 0 1004 0 0996 in washer 383775200 2 45 0 0965 383785200 2 43 0 0957 383795200 2 41 0 0949 383805200 2 39 0 0941 383815200 2 37 0 0933 383825200 2 35 0 0925 383835200 2 33 0 0917 383845200 2 31 0 0909 Part No Length mm in 383695201 56 2 2 213 383695202 56 4 2 220 E Preload adjusting 383695203 56 6 2 228 Spacer 383695204 56 8 2 236 383695205 57 0 2 244 383695206 57 2 2 252 3 Adjusting drive pinion height Adjust drive pinion height with shim installed between rear bearing cone and the back of pinion gear 1 Install ST1 ST2 and ST3 as shown in the figure and apply the specified preload on the bearings Front and rear bearing preload For new bearing 19 6 28 4 N 2 0 2 9 kgf 4 4 6 4 Ib at companion flange bolt hole For used bearing 8 34 16 67 N 0 85 1 7 kgf 1 87 3 75 Ib at companion flange bolt hole Adjusting preload for front and rear bearings NOTE At this time install a pinion height adjusting shim which is temporarily selected or the same as that used before Measure and record the thickness ST1 398507702 DUMMY SHAFT ST2 398507701 GAUGE ST3 398507703 DUMMY COLLAR 01 32 REAR DIFFE
18. 5 Noises when cornering 6 Gear noises NOTE Since noises from engine muffler transmission propeller shaft wheel bearings tires and body are sometimes mistaken for noises from differential assembly be careful in checking them Inspection methods to locate noises include coasting accelerating cruising and jacking up all four wheels Perform these inspections according to condition of trouble When listening to noises shift gears into four wheel drive and fourth speed position trying to pick up only dif ferential noise Excessive backlash for hypoid gear Readjust Excessive backlash for differential gear Replace gear or thrust washer Insufficient preload for front or rear bear ing Readjust Loose drive pinion nut Tighten to specified torque Loose bolts and nuts such as side bear ing retainer attaching bolt Tighten to specified torque Damaged differential gear Replace Excessive wear or damage of thrust washer Replace Broken pinion mate shaft Replace Seized or damaged side bearing Replace Improper tooth contact of hypoid gear Readjust or replace hypoid gear set Improper backlash for hypoid gear Readjust Scored or chipped teeth of hypoid gear Seized hypoid gear Replace hypoid gear set Replace hypoid gear set Improper preload for front or rear bear ings Seized scored or chipped front or rear bearing Seized scored or chip
19. 85200 2 43 mm 0 0957 in 383795200 2 41 mm 0 0949 in 383805200 2 39 mm 0 0941 in 383815200 2 37 mm 0 0933 in 383825200 2 35 mm 0 0925 in 383835200 2 33 mm 0 0917 in 383845200 2 31 mm 0 0909 in 383495200 3 09 mm 0 1217 in 383505200 3 12 mm 0 1228 in 383515200 3 15 mm 0 1240 in 383525200 3 18 mm 0 1252 in 383535200 3 21 mm 0 1264 in 383545200 3 24 mm 0 1276 in 383555200 3 27 mm 0 1287 in 383565200 3 30 mm 0 1299 in 383575200 3 33 mm 0 1311 in 383585200 3 36 mm 0 1323 in 383595200 3 39 mm 0 1335 in 383605200 3 42 mm 0 1346 in 383615200 3 45 mm 0 1358 in 383625200 3 48 mm 0 1370 in 383635200 3 51 mm 0 1382 in 383645200 3 54 mm 0 1394 in 383655200 3 57 mm 0 1406 in 383665200 3 60 mm 0 1417 in 383675200 3 63 mm 0 1429 in 383685200 3 66 mm 0 1441 in 383445201 0 75 0 80 mm 0 0295 0 0315 in 383445202 0 80 0 85 mm 0 0315 0 0335 in Side gear thrust washer 383445203 0 85 0 90 mm 0 0335 0 0354 in 383445204 0 90 0 95 mm 0 0354 0 0374 in 383445205 0 95 1 0 mm 0 0374 0 0394 in Pinion height adjusting shim DI 5 Differentials GENERAL DESCRIPTION Part No Length or thickness Side bearing retainer shim 383475201 0 20 mm 0 0079 in 383475202 0 25 mm 0 0098 in 383475203
20. 89 38336AA220 1 763 0 0694 38336AA110 1 775 0 0699 Part No Length mm in 32288AA040 52 3 32288AA050 31454AA100 Preload adjusting 32288AA060 spacer 31454AA110 32288AA070 31454AA120 32288AA080 38336AA210 1 738 0 0684 SKS Hy H3M1309B 3 Adjusting drive pinion height Adjust drive pinion height with shim installed between rear bearing cone and the back of pinion gear 1 Install ST1 ST2 and ST3 as shown in the figure and apply the specified preload on the bearings Front and rear bearing preload For new bearing 12 7 32 4 N 1 3 3 3 kgf 2 9 7 3 Ib at companion flange bolt hole Adjusting preload for front and rear bearings NOTE At this time install an original pinion height adjust ing shim ST1 498447150 DUMMY SHAFT ST2 32285AA000 DUMMY COLLAR DI 49 REAR DIFFERENTIAL FOR VA TYPE Differentials 3 Obtain the thickness of pinion height adjust ing washer to be inserted from the following formula and replace the temporarily installed shim with this one NOTE Use 1 to 3 shims as required for adjustment T To N 0 05 mm where T Thickness of pinion height adjusting shim mm To Thickness of shim originally installed mm N Reading of thickness gauge mm H Figure marked on drive pinion head Example of calculation To 0 15 mm N 0 1 mm T 2 0 15 0 1 0 05 0 2
21. E When installing rear differential front member do not confuse the installation sequence of the upper and lower stoppers 3 Install DOJ of rear drive shaft into rear differen tial ST 28099PA090 SIDE OIL SEAL PROTEC TOR ST F SS J ui DES G3M1026 4 Install in the reverse order of removal 5 After installing rear differential carrier on vehicle remove filler plug and replenish gear oil up Ref to DI 22 Differential Gear Oil 6 Connect connector to rear differential tempera ture sensor Turbo model for Europe 7 If the results of the following inspections are not satisfactory check rear differential temperature sensor and circuit Then repair or replace if neces sary 1 Check that rear differential temperature sensor warning light lights up when ignition switch is turned to on engine stopped 2 Start engine then check that the warning light goes off after a few seconds DI 27 REAR DIFFERENTIAL FOR T TYPE Differentials DISASSEMBLY S303145A06 To detect real cause of trouble inspect the follow ing items before disassembling e Tooth contact of crown gear and pinion and backlash e Runout of crown gear at its back surface e Turning resistance of drive pinion 1 Set ST on vise and install the differential assembly to ST ST 398217700 ATTACHMENT SET G3M1031 2 Drain gear oil by removing plug 3 Remove the air breather cap NOTE Do not attempt
22. IDE OIL SEAL PROTEC TOR 4 Completely insert DOJ into rear differential by pressing rear housing NOTE Make sure that oil seal lip is not folded over inward H4M1095 14 Install in the reverse order of removal 2 D T TY P E 5303137 2001 1 Set vehicle a lift 2 Disconnect ground terminal from battery 3 Move select lever or gear shift lever to N 4 Release the parking brake 5 Loosen both wheel nuts Differentials 6 Jack up the vehicle and support it with rigid racks 7 Remove wheels 8 Remove rear exhaust pipe and muffler Non turbo model with OBD Ref to EX SOHC 9 REMOVAL Rear Exhaust Pipe and Ref to EX SOHC 11 REMOVAL Muffler gt Non turbo model without OBD Ref to EX SOHCw oOBD 10 REMOVAL Rear Exhaust Pipe and Ref to EX SOHCw oOBD 12 REMOVAL Muffler gt Turbo model Ref to EX DOHC TURBO 14 REMOVAL Rear Exhaust Pipe and Ref to EX DOHC TURBO 15 REMOVAL Muffler gt 9 Remove the DOJ of rear drive shaft from rear differential 1 Remove the ABS sensor cable clamp and parking brake cable guide from bracket H3M1397B A ABS sensor cable clamp B Parking brake cable guide 2 Remove the ABS sensor cable clamp from the trailing link H3M1398 DI 63 REAR DIFFERENTIAL SIDE OIL SEAL Differentials 3 Remove the ABS sensor cable clamp and 7 Remove the DOJ from the rear diffe
23. LER e Used for installing rear bearing cone e For VA type B3M1921 399780111 WRENCH ASSY e Used for removing and installing side oil seal holder e For VA type B3M1922 B3M1923 498447100 399520105 INSTALLER DI 18 e Used for installing oil seal e For VA type e Used for removing side bearing cone e Used with PULLER SET 899524100 e For VA type ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION Differentials REMARKS B3M1924 498485400 DRIFT 498505501 e UUsed for installing side bearing cone e For VA type e Used for adjusting pinion height e For VA type B3M1927 498447110 BEARING OUTER RACE DRIFT 498447150 DUMMY SHAFT DI 19 e Used for press fitting the bearing race front of differential carrier e For VA type e Used for adjusting pinion height and Pre load e For VA type Differentials ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION REMARKS B3M1928 B3M1929 32285AA000 499705404 DUMMY COLLAR e Used for adjusting pinion height and Pre load e For VA type e Used for removing side bearing race e Used with PULLEY ASSY 499705401 e For VA type B3M1930 499705401 PULLEY ASSY e Used for removing side bearing race e Used with SEAT 499705404 e For VA type LOOT SY MAA AAA AG B3M1931 899874100 INSTALLER e Used for installing companion flange e F
24. M1052 DI 34 REAR DIFFERENTIAL FOR T TYPE 11 Assembling differential case Install side gears and pinion mate gears with their thrust washers and pinion mate shaft into differen tial case CAUTION e Apply gear oil on both sides of the washer and on the side gear shaft before installing e Insert the pinion mate shaft into the differen tial case by aligning the lock pin holes gt a 2 2 G3M0089 Differentials 1 Measure the side gear backlash Side gear back clearance 0 10 0 20 mm 0 0039 0 0079 in 7 B3M1933 2 Adjust the backlash as specified by select ing side gear thrust washer Thickness mm in 0 75 0 80 0 0295 0 0315 0 80 0 85 0 0315 0 0335 0 85 0 90 0 0335 0 0354 0 90 0 95 0 0354 0 0374 0 95 1 00 0 0374 0 0394 3 Check the condition of rotation after apply ing oil to the gear tooth surfaces and thrust sur faces 4 After inserting pinion shaft lock pin into dif ferential case stake the both sides of the hole to prevent pin from falling off 12 Install crown gear on differential case CAUTION Before installing bolts apply Lock Tite to bolt threads Lock Tite THREE BOND 1324 or equivalent NOTE Tighten diagonally while tapping the bolt heads Tightening torque 103 N m 10 5 kgf m 76 ft lb S3M0509 DI 35 REAR DIFFERENTIAL FOR T T
25. R T TYPE Differentials 15 Remove DOJ of rear drive shaft from rear dif 18 Support rear differential with transmission ferential using ST lt Ref to DS 38 REMOVAL jack Rear Drive Shaft gt ST 28099PA100 DRIVE SHAFT REMOVER 53 0505 19 Remove self locking nuts connecting rear dif H3M1179B n ferential to rear crossmember A Bolt B DOJ A 16 Secure rear drive shaft to rear crossmember using wire G3M1028 20 Remove bolts which secure rear differential front member to body 1 Loosen bolt A first then remove bolts B S3M0500 NOTE 17 Remove lower differential bracket Support front member with a help of an assistant to prevent it from dropping S3M0529 B3M0657C A BoltA B BoltB 2 Remove bolt A DI 26 REAR DIFFERENTIAL FOR T TYPE 21 While slowly lowering transmission jack move rear differential forward and remove bolts from rear crossmember 22 Remove front member from body G3M1029 23 Remove rear differential from body G3M1030 Differentials B INSTALLATION gt To install reverse the removal sequence 1 Install the air breather cap tapping with a plas tic hammer CAUTION Be sure to install new air breather cap 2 Position front member on body by passing it under parking brake cable and securing to rear differential NOT
26. RENTIAL FOR T TYPE Differentials ST3 ST1 RH N ST2 S3M0518B A Pinion height adjusting shim 2 Measure the clearance N between the end of ST2 and the end surface of ST1 by using a thickness gauge NOTE Make sure there is no clearance between the case and ST2 ST1 398507702 DUMMY SHAFT ST2 398507701 GAUGE H3M1309B 3 Obtain the thickness of pinion height adjust ing shim to be inserted from the following formula and replace the temporarily installed shim with this one T To N H x 0 01 0 20 mm 0 0079 in NOTE Use copies of this page Thickness of shim temporarily inserted mm in Thickness of pinion height adjusting shim mm in Reading of thickness gauge mm in H Figure marked on drive pinion head Memo Example of calculation To 2 2 20 4 1 20 2 3 40 mm N2 0 23 mm H 1 T 3 40 0 23 0 01 0 20 3 42 Result Thickness 3 42 mm Therefore use the shim 383605200 383525200 3 18 0 1252 383535200 3 21 0 1264 383545200 3 24 0 1276 383555200 3 27 0 1287 383565200 3 30 0 1299 383575200 3 33 0 1311 383585200 3 36 0 1323 383595200 3 39 0 1335 383605200 3 42 0 1346 383615200 3 45 0 1358 383625200 3 48 0 1370 383635200 3 51 0 1382 383645200 3 54 0 1394 383655200 3 57 0 1406 383665200 3 60 0
27. YPE Differentials 13 Press side bearing cone onto differential case 4 Align arrow marked on differential carrier with ST with that marked on side retainer during instal ST 398487700 DRIFT lation CAUTION Be careful that side bearing outer race is not damaged by bearing roller G3M0091 14 Adjusting side bearing retainer shims 1 The driven gear backlash and side bearing preload can be determined by the side bearing retainer shim thickness 2 Install the differential case assembly into differential carrier in the reverse order of disas 5 Tighten side bearing retainer bolts sembly CAUTION Before tightening the two side bearing retainer bolts apply Lock Tite to bolt threads Lock Tite THREE BOND 1105 or equivalent Tightening torque 10 3 N m 1 05 kgf m 7 6 ft lb A Arrow mark S3M0533 3 Install side retainer shims and O rings to the left and right retainers from which they were removed NOTE e Replace broken or cracked O ring with new one e Replace broken or corroded side retainer shim S3M0173 with new one of same thickness Side bearing retainer shim Part No Thickness mm in 383475201 0 20 0 0079 383475202 0 25 0 0098 383475203 0 30 0 0118 383475204 0 40 0 0157 383475205 0 50 0 0197 DI 36 REAR DIFFERENTIAL FOR T TYPE 6 Measure the crown gear to drive pinion backlash Set mag
28. ar stabilizer link H3M1396 5 Remove the bolts which secure the trailing link to the rear housing G3M0042 REAR DIFFERENTIAL SIDE OIL SEAL Differentials 6 Remove the bolts which secure the front and rear lateral link to the rear housing G3M0043 7 Remove the DOJ from the rear differential with tire lever CAUTION When removing the DOJ from the rear differential fit tire lever to the bolt as shown in figure so as not to damage the axle shaft holder NOTE The side spline shaft circlip comes out together with the shaft H3M1664B A Tire lever B Axle shaft holder 10 Secure rear drive shaft to rear crossmember using wire S3M0500 11 Remove oil seal with screwdriver S3M0501A A Side oil seal B Screwdriver 12 Drive in a new side oil seal with ST CAUTION Apply chassis grease between the oil seal lips ST 498447100 OIL SEAL INSTALLER G3M0048 13 Insert the DOJ into rear differential CAUTION Before inserting replace the circlip at the end of the spline shaft with a new one DI 62 REAR DIFFERENTIAL SIDE OIL SEAL 1 Install ST to rear differential ST 28099PA090 SIDE OIL SEAL PROTEC TOR G3M0256 2 Insert the spline shaft until the spline portion is inside the side oil seal G3M0049 3 Remove ST ST 28099PA090 S
29. breather Clean repair or replace Loose bolts on differential spindle or side retainer or incorrectly fitted O ring Tighten bolts to specified torque Replace O ring Loose rear cover attaching bolts or dam aged gasket Tighten bolts to specified torque Replace gasket and apply liquid packing Loose oil filler or drain plug Retighten and apply liquid packing Wear damage or incorrectly fitting for spindle side retainer and oil seal Insufficient backlash for hypoid gear Repair or replace Readjust or replace Excessive preload for side rear or front bearing Readjust or replace Insufficient or improper oil used Replace seized part and fill with speci fied oil to specified level 3 Damage NOTE Damaged parts should be replaced and also other parts should be thoroughly checked for any defect and should be repaired or replaced as required Improper backlash for hypoid gear Replace Insufficient or excessive preload for side rear or front bearing Readjust or replace Excessive backlash for differential gear Replace gear or thrust washer Loose bolts and nuts such as crown gear bolt Retighten Damage due to overloading Replace 4 Noises when starting or shifting gears NOTE Noises may be caused by differential assembly universal joint wheel bearing etc Find out what is actually making noise before disassembly
30. carrier e For T type B3M1908 398437700 DI 15 e Used for installing said oil seal e For T type GENERAL DESCRIPTION Differentials ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507702 DUMMY SHAFT e Used for adjusting pinion height and preload e For T type B3M1909 398507703 DUMMY COLLAR e Used for adjusting pinion height and preload e For T type 398517700 REPLACER e Used for removing rear bearing cone e For T type 398487700 e Used for press fitting the side bearing cone e For T type 398507701 e Used for adjusting pinion height e For T type B3M1913 DI 16 ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION Differentials REMARKS B3M1915A 398527700 PULLER ASSY 399527700 PULLER SET e Used for removing oil seal and side bearing cup e For T type e Used for extracking side bearing cone BOLT 899521412 PULLER 399527702 HOLDER 399527703 ADAPTER 398497701 BOLT 899520107 NUT 021008000 e For T type B3M1917 28099PA090 OIL SEAL PROTEC TOR e Used for installing rear drive shaft into rear differential e For protecting oil seal e For T type B3M1919 28099PA100 DRIVE SHAFT REMOVER DI 17 e Used for removing rear drive shaft from rear differential e For T type Differentials ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION REMARKS B3M1920 498175500 INSTAL
31. ecuring to rear differential 3 4 5 G3M0058 NOTE When installing rear differential front member do not confuse the installation sequence of the stop per H3M1402B A Stopper B Differential mount bracket 2 Insert DOJ of rear drive shaft into rear differen tial ST 28099PA090 SIDE OIL SEAL PROTEC TOR CAUTION Before inserting replace the differential side oil seal and the circlip at the end of the spline shaft with a new one G3M0049 3 Install in the reverse order of removal INSPECTION S303135A10 1 Check rear differential member for damage bend or corrosion If damage bend or corrosion is excessive replace rear differential member 2 Check bushings of rear differential member for cracking hardening or damage If cracking hardening or damage is excessive replace rear differential member DI 66 GENERAL DIAGNOSTIC TABLE Differentials 9 General Diagnostic A INSPECTION Ta b 5303257 Symptom or trouble Possible cause Remedy 1 Oil leakage 2 Seizure NOTE Seized or damaged parts should be replaced and also other parts should be thoroughly checked for any defect and should be repaired or replaced as required Worn scratched or incorrectly seated front or side oil seal Scored battered or excessively worn sliding surface of com panion flange Repair or replace Clogged or damaged air
32. er mix up the right and left hand bearing races and cones ST1 899524100 PULLER SET ST2 399520105 SEAT H3M1970A 11 Remove crown gear by loosening crown gear bolts S3M0509 DI 45 REAR DIFFERENTIAL FOR VA TYPE Differentials 12 Drive out pinion shaft lock pin from crown gear side NOTE The lock pin is staked at the pin hole end on the differential case do not drive it out forcibly before unstaking it ST 899904100 STRAIGHT PIN REMOVER B3M0133 13 Draw out pinion mate shaft and remove pinion mate gears side gears and thrust washers NOTE The gears as well as thrust washers should be marked or kept separated left and right and front and rear A NAI B B reg C S3M0510A Side gear Pinion mate gear Thrust washer Differential case Pinion mate shaft CELLE 14 Hold companion flange with ST and remove self locking nut ST 498427200 FLANGE WRENCH Ti T 15 Extract the companion flange with a puller S3M0511A A Companion B Puller 16 Press the end of drive pinion shaft and extract it together with rear bearing cone preload adjust ing spacer and washer NOTE Hold the drive pinion so as not to drop it ST 398467700 DRIFT G3M0074 DI 46 REAR DIFFERENTIAL FOR VA TYPE Differentials 17 Remove rear bearing cone from drive pinion by sup
33. ferential of manual transmission refer to MT section lt Ref to MT 92 Front Differential Assembly gt 01 24 REAR DIFFERENTIAL FOR T TYPE 4 Rear Differential for T type 5303145 REMOVAL 5303145 18 1 Set vehicle on a lift 2 Disconnect ground terminal from battery 3 Move select lever or gear shift lever to N 4 Release the parking brake 5 Loosen wheel nuts 6 Jack up vehicle and support it with sturdy racks 7 Remove wheels 8 Remove rear exhaust pipe and muffler Non turbo model with OBD Ref to EX SOHC 9 REMOVAL Rear Exhaust Pipe and Ref to EX SOHC 11 REMOVAL Muffler gt Non turbo model without OBD lt Ref to EX SOHCw oOBD 10 REMOVAL Rear Exhaust Pipe and Ref to EX SOHCw oOBD 12 REMOVAL Muffler gt Turbo model Ref to EX DOHC TURBO 14 REMOVAL Rear Exhaust Pipe and Ref to EX DOHC TURBO 15 REMOVAL Muffler gt 9 Remove front exhaust cover Non Turbo model S3M0502 10 Remove front cover of rear differential mount S3M0503 11 Remove propeller shaft Ref to 05 14 REMOVAL Propeller Shaft Differentials 12 Remove heat sealed cover S2M0166 13 Remove clamps and bracket of parking brake cable S2M0191 14 Disconnect connector from oil temperature sensor Turbo model for Europe S3M0615A A Connector DI 25 REAR DIFFERENTIAL FO
34. for T type gt DI 41 REAR DIFFERENTIAL FOR VA TYPE Differentials 5 Rear Differential for VA type 5303151 REMOVAL 5303151 18 1 Set vehicle on a lift 2 Disconnect ground terminal from battery 3 Move select lever or gear shift lever to N 4 Release the parking brake 5 Loosen wheel nuts 6 Jack up vehicle and support it with sturdy racks 7 Remove wheels 8 Remove rear exhaust pipe and muffler With OBD lt Ref to EX SOHC 9 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX SOHC 11 REMOVAL Muffler gt Without OBD lt Ref to EX SOHCw oOBD 10 REMOVAL Rear Exhaust Pipe and Ref to EX SOHCw oOBD 12 REMOVAL Muffler gt 9 Remove front exhaust cover S3M0502 10 Remove front cover of rear differential mount S3M0503 11 Remove propeller shaft Ref to 05 14 REMOVAL Propeller Shaft 12 Remove heat sealed cover S2M0166 13 Remove clamps and bracket of parking brake cable S2M0191 14 Remove DOJ of rear drive shaft from rear dif ferential Ref to DS 38 REMOVAL Rear Drive Shaft S3M0504A A DOJ B Tire lever DI 42 REAR DIFFERENTIAL FOR VA TYPE 15 Secure rear drive shaft to rear crossmember using wire S3M0500 16 Remove lower differential bracket Dy A 3 H3M1273B A Lower differential bracke
35. g spacer Bearing preload adjusting washer Differential carrier Front bearing Collar Pilot bearing Front oil seal Companion flange 2 Self locking nut 3 Side bearing 4 O ring 5 Side bearing retainer shim 6 Side bearing retainer 7 Side oil seal 8 Gasket 9 Differential case 0 Rear cover 1 Air breather cap 2 1 1 1 1 1 1 1 1 2 2 22 Stud bolt DI 8 23 Oil filler plug With oil tempera ture sensor 24 Oil filler plug Without oil tem perature sensor 25 Oil drain plug Tightening torque N m kgf m ft lb T1 10 3 1 05 7 6 T2 29 3 0 21 7 T3 49 0 5 0 36 2 T4 103 10 5 76 T5 181 18 5 134 GENERAL DESCRIPTION Differentials 3 REAR DIFFERENTIAL FOR VA TYPE S303001A0503 H3M1663A Pinion crown gear set Pinion height adjusting shim Rear bearing Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier Front bearing Collar Pilot bearing Front oil seal Companion flange Self locking nut KKK GEGEE wo ONO re e 3 Lock plate 4 Side bearing 5 O ring 6 Axle shaft holder 7 Side oil seal 8 Side gear thrust washer 9 Side gear 0 Pinion mate gear 1 Pinion shaft lock pin 2 Differential case 3 Pinion mate shaft 4 Air breather cap 5 1 1 1 1 1 1 1 2 2 2 2 2 25 Stud bolt
36. gear backlash 0 1 0 2 mm 0 004 0 008 in If crown gear backlash is not within the specification adjust the side bearing preload or repair if necessary G3M1047 3 CROWN GEAR RUNOUT S303145A1003 Using a dial gauge check the crown gear runout Crown gear runout Less than 0 05 mm 0 0020 in If the crown gear runout exceeds 0 05 mm 0 0020 in replace the crown gear S3M0525 4 TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION Inspect tooth contact between crown gear and driven pinion Ref to DI 31 ASSEMBLY Differen tial for T type Differentials 5 TOTAL PRELOAD S303145A 1005 Using a gauge check the turning resistance increase Total preload 2 9 10 8 0 3 1 1 kgf 0 7 2 4 Ib If the increase of the resistance is not within the specification adjust the side bearing retainer shims B3M1935 F ADJUSTMENT S303145A01 1 SIDE GEAR BACKLASH o Adjust side gear backlash Ref to DI 81 ASSEMBLY Differential for T type gt 2 CROWN GEAR BACKLASH aren Adjust crown gear backlash Ref to 01 31 ASSEMBLY Differential for T type gt 3 TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION 41540108 Adjust the tooth contact between crown gear and drive pinion_gear Ref to 01 81 ASSEMBLY Differential for T type gt 4 TOTAL PRELOAD A303145A0104 Adjust side bearing shim lt Ref to DI 81 ASSEMBLY Differential
37. height changing RH and LH side bearing retainer shims and the hypoid gear backlash G3M1047 DI 37 REAR DIFFERENTIAL FOR T TYPE Differentials 1 Drive pinion height 2 Hypoid gear backlash ST1 398507702 DUMMY SHAFT Backlash ST2 398507701 GAUGE 0 10 0 20 mm 0 0039 0 0079 in H3M1309B G3M1047 T To N Hx 0 01 0 20 mm Where T Thickness of pinion height adjusting shim mm To Thickness of shim temporarily inserted mm N Reading of thickness gauge mm H Figure marked on drive pinion head DI 38 REAR DIFFERENTIAL FOR T TYPE TOOTH CONTACT PATTERN Differentials Condition Contact pattern Adjustment Correct tooth contact Tooth contact pattern slightly shifted towards toe under no load rotation When loaded contact pattern moves toward heel Toe side A Heel side G3M0098A Face contact Backlash is too large This may cause noise and chipping at tooth ends G3M0098B Increase thickness of drive pinion height adjusting shim in order to bring drive pin ion closer to crown gear center G3M0098F Flank contact Backlash is too small This may cause noise and stepped wear on surfaces G3M0098C Reduce thickness of drive pinion height adjusting shim in order to move drive pinion away from crown gear 4 G3M0098G Toe contact Contact area is small Heel contact Contact area is small
38. ide gear and pinion mate gear Replace if seizure flaw abnormal wear or other defect is evident 5 Oil seal Replace if deformed or damaged and at every disassembling 6 Differential carrier Replace if the bearing bores are worn or damaged 7 Differential case Replace if its sliding surfaces are worn or cracked 8 Companion flange Replace if the oil seal lip contacting surfaces have flaws 9 Rear differential oil temperature sensor Turbo model for Europe If the results of the following inspections are not satisfactory replace rear differential temperature sensor 1 At room temperature check for continuity between the sensor terminal and body 2 Soak the sensor in oil then raise the oil temperature Check that the continuity is cut off when the oil temperature is between 144 C 291 F and 156 C 313 F Then check that the continuity resumes by the time the oil tem perature drops to 135 C 275 CAUTION The oil is hot so be careful not to burn yourself when inspecting 1 SIDE GEAR BACKLASH so Using a dial gauge check the backlash of the side gear Side gear backlash 0 1 0 2 mm 0 004 0 008 If side gear backlash is not within the specification adjust clearance as specified by selecting side gear thrust washer B3M1934 01 40 REAR DIFFERENTIAL FOR T TYPE 2 CROWN GEAR BACKLASH sssoz Using a dial gauge check the backlash of the crown gear Crown
39. ight adjusting washer and rear bearing cone fitted onto it CAUTION e Re use the used washer if not deformed e Use a new rear bearing cone 3 Then install preload adjusting spacer and washer front bearing cone ST2 companion flange and washer and drive pinion nut ST1 398507702 DUMMY SHAFT ST2 398507703 DUMMY COLLAR A S3M0516A A Pinion height adjusting shim B Preload adjusting spacer C Preload adjusting washer DI 31 REAR DIFFERENTIAL FOR T TYPE Differentials 4 Turn ST1 with hand to make it seated and tighten drive pinion nut while measuring the pre load with spring balance Select preload adjust ing washer and spacer so that the specified pre load is obtained when nut is tightened to the specified torque CAUTION Use a new lock nut NOTE e Be careful not to give excessive preload e When tightening the drive pinion nut lock ST1 with ST2 as shown in the figure ST1 398507704 BLOCK ST2 398507702 DUMMY SHAFT Tightening torque 181 18 5 kgf m 134 ft lb G3M1038 Front and rear bearing preload For new bearing 19 6 28 4 N 2 0 2 9 kgf 4 4 6 4 Ib at companion flange bolt hole For used bearing 8 34 16 67 N 0 85 1 7 kgf 1 87 3 75 Ib at companion flange bolt hole ST2 ST1 RH ST3 S3M0518A Part No 383705200 383715200 383725200 383735200 2 53
40. insert DOJ into rear differential by pressing rear housing NOTE Make sure that oil seal lip is not folded over inward S Y IN G3M0050 14 Install in the reverse order of removal DI 65 REAR DIFFERENTIAL MEMBER Differentials 8 Rear Differential Member A REMOVAL S303135A18 1 Set vehicle on a lift 2 Disconnect ground terminal from battery Move select lever or gear shift lever to Release the parking brake Loosen wheel nuts 6 Jack up vehicle and support it with sturdy racks 7 Remove wheels 8 Remove rear exhaust pipe and muffler Non turbo model with OBD lt Ref to EX SOHC 9 REMOVAL Rear Exhaust Pipe gt and lt Ref to EX SOHC 11 REMOVAL Muffler gt Non turbo model without OBD Ref to EX SOHCw oOBD 10 REMOVAL Rear Exhaust Pipe and Ref to EX SOHCw oOBD 12 REMOVAL Muffler gt Turbo model Ref to EX DOHC TURBO 14 REMOVAL Rear Exhaust Pipe and Ref to EX DOHC TURBO 15 REMOVAL Muffler gt 9 Remove rear differential front member VA type Ref to DI 42 REMOVAL Rear Differential for VA type gt T type lt Ref to 25 REMOVAL Rear Differential for T type gt NOTE When removing rear differential front member work the removal procedure as rear differential B INSTALLATION sss To install reverse the removal sequence 1 Position front member on body by passing it under parking brake cable and s
41. iving in pinion shaft lock pin stake the both sides of the hole to prevent from 2 Install bearing race into right and left hold falling off ers 5 Install crown gear on differential case ST 398477702 DRIFT CAUTION Before installing bolts apply Lock Tite to bolt Ab 7 threads Lock Tite THREE BOND 1324 or equivalent NOTE Tighten diagonally while tapping the bolt heads Tightening torque 62 6 3 kgf m 45 6 ft lb G3M0093 S3M0509 DI 52 REAR DIFFERENTIAL FOR VA TYPE 3 Install the differential case assembly into differential carrier in the reverse order of disas sembly G3M0065 14 Perform adjustment of backlash of pinion crown gear set and adjustment of preload of differ ential side bearing 1 Turn drive pinion with ST for better fitting of differential side bearing ST 498427200 FLANGE WRENCH G3M0094 2 Screw in side left side holder until light contact is made with ST ST 399780111 WRENCH G3M0064 3 Back off side left side holder approxi mately 1 1 2 teeth of holder and tighten left side holder by approximately 2 teeth approximately 1 1 2 1 2 teeth Back off amount of side left side holder 1 2 tooth This 1 2 tooth gives preload Differentials 4 Temporarily tighten lock plate NOTE Turn over lock plate to displace holder 1 2 tooth G3M0063 5 Measure
42. m crown gear side NOTE The lock pin is staked at the pin hole end on the differential carrier do not drive it out forcibly before unstaking it ST 899904100 STRAIGHT PIN REMOVER B3M0133 11 Draw out pinion mate shaft and remove pinion mate gears side gears and thrust washers NOTE The gears as well as thrust washers should be marked or kept separated left and right and front and rear A B 0 m S3M0510A Side gear Pinion mate gear Thrust washer Differential case Pinion mate shaft m9 our 01 29 REAR DIFFERENTIAL FOR T TYPE Differentials 12 Hold companion flange with ST and remove drive pinion nut ST 498427200 FLANGE WRENCH G3M1052 13 Extract the companion flange with a puller lt S3M0511 14 Press the end of drive pinion shaft and extract it together with rear bearing cone preload adjust ing spacer and washer NOTE Hold the drive pinion so as not to drop it ST 398467700 DRIFT G3M0074 15 Remove rear bearing cone from drive pinion by supporting cone with ST NOTE Place the replacer so that its center recessed side faces the pinion gear ST 398517700 REPLACER S3M0512A 16 Remove front oil seal from differential carrier using ST ST 398527700 PULLER ASSY S3M0513 17 Remove pilot bearing together with front bear ing cone using
43. nd washer between front and rear bearings Pinion height adjusting washer are not affected by this adjust ment The adjustment must be carried out without oil seal inserted DI 47 REAR DIFFERENTIAL FOR VA TYPE Differentials 1 Press rear bearing race into differential car rier with ST1 and ST2 ST1 398477701 HANDLE ST2 398477702 DRIFT 2 Press front bearing race into differential car rier with ST1 and ST2 ST1 398477701 HANDLE ST2 498447110 DRIFT G3M0080 3 Insert front bearing cone CAUTION Use a new front bearing cone 4 Insert ST1 into case with pinion height adjusting shim and rear bearing cone fitted onto it CAUTION e Re use the used washer if not deformed e Use a new rear bearing cone 5 Then install preload adjusting spacer and washer front bearing cone ST2 companion flange and washer and self locking nut ST1 498447150 DUMMY SHAFT ST2 32285AA000 DUMMY COLLAR A S3M0516A A Pinion height adjujusting shim B Preload adjusting spacer C Preload adjusting washer 6 Turn ST1 with hand to make it seated and tighten drive pinion nut while measuring the pre load with spring balance Select preload adjust ing washer and spacer so that the specified pre load is obtained when nut is tightened to the specified torque CAUTION Use a new self locking nut NOTE e Be careful not to give excessive preload e When tightening the d
44. net base on differential car rier Align contact point of dial gauge with tooth face of crown gear and move crown gear while holding drive pinion still Read value indicated on dial gauge Backlash 0 10 0 20 mm 0 0039 0 0079 in G3M1047 7 At the same time measure the turning resistance of drive pinion Compared with the resistance when differential case is installed if the increase of the resistance is not within the specified range readjust side bearing retainer shims Differentials 16 Check the crown gear runout on its back surface and make sure pinion and crown gear rotate smoothly Limit of runout Less than 0 05 mm 0 0020 in S3M0525 17 Checking and adjusting tooth contact of crown gear 1 Apply an even coat of red lead on both sides of three or four teeth on the crown gear Check the contact pattern after rotating crown gear several revolutions back and forth until a definite contact pattern appears on the crown gear 2 When the contact pattern is incorrect read just according to the instructions given in Turning resistance increase TOOTH CONTACT PATTERN 2 9 10 8 N 0 3 1 1 kgf 0 7 2 4 Ib NOTE 15 Re check crown gear to pinion backlash Be sure to wipe off red lead completely after adjustment is completed Backlash 0 10 0 20 mm 0 0039 0 0079 in 18 If proper tooth contact is not obtained once again adjust the drive pinion
45. nite contact pattern appears on the crown gear 2 When the contact pattern is incorrect read just according to the instructions given in TOOTH CONTACT PATTERN NOTE Be sure to wipe off red lead completely after adjustment is completed 20 If proper tooth contact is not obtained once again adjust the drive pinion height and the differ ential side bearing preload already mentioned and the hypoid gear backlash 1 Drive pinion height ST1 498447150 DUMMY SHAFT ST2 498505501 DIFFERENTIAL GAUGE H3M1309B T To N 0 05 mm where T Thickness of pinion height adjusting shim mm To Thickness of shim originally installed mm DI 54 REAR DIFFERENTIAL FOR VA TYPE Differentials N Reading of thickness gauge mm 3 Hypoid gear backlash 2 Differential side bearing preload Backlash Screw in side left side holder until light contact 0 10 _ 0 15 mm 0 0039 0 0059 in is made with ST Back off side left side holder approximately 1 1 2 teeth of holder and tighten left side holder by approximately 2 teeth approximately 1 1 2 1 2 teeth Back off amount of side left side holder 1 2 tooth This 1 2 tooth gives preload ST 399780111 WRENCH G3M0064 DI 55 REAR DIFFERENTIAL FOR VA TYPE Differentials TOOTH CONTACT PATTERN Condition Contact pattern Adjustment Correct tooth contact Tooth contact pattern slightly shifted t
46. ontact at assembly Replace the gear if excessively worn or incapable of adjustment e f crack score or seizure is evident replace as a set Slight damage of tooth can be corrected by oil stone or the like 2 Side gear and pinion mate gear e Replace if crack score or other defects are evi dent on tooth surface e Replace if thrust washer contacting surface is worn or seized Slight damage of the surface can be corrected by oil stone or the like 3 Bearing Replace if seizure peeling wear rust dragging during rotation abnormal noise or other defect is evident 4 Thrust washers of side gear and pinion mate gear Replace if seizure flaw abnormal wear or other defect is evident 5 Oil seal Replace if deformed or damaged and at every disassembling 6 Differential carrier Replace if the bearing bores are worn or damaged 7 Differential case Replace if its sliding surfaces are worn or cracked 8 Companion flange Replace if the oil seal lip contacting surfaces have flaws Differentials 1 SIDE GEAR BACKLASH ao Using a dial gauge check the backlash of the side gear Side gear backlash 0 05 0 15 mm 0 0020 0 0059 in If side gear backlash is not within the specification adjust clearance as specified by selecting side gear trust washer B3M1934 2 CROWN GEAR BACKLASH arsa Using a dial gauge check the backlash of the crown gear Crown gear backlash 0 10 0 15 mm
47. or VA type B3M1932A 899524100 DIFFERENTIAL BEARING PULLER SET 01 20 e Used for removing side bearing of dif ferential e For VA type 1 Puller 2 Cap e Used with SEAT 399520105 GENERAL DESCRIPTION Differentials 2 GENERAL PURPOSE TOOLS oam TOOL NAME REMERKS Transmission Jack Used for assembly disassembly of rear differential Puller Used for removal of side bearing retainer T type Thickness Gauge Used for measuring clearance Tire Lever Used for removal of rear drive shaft VA type DI 21 DIFFERENTIAL GEAR OIL Differentials 2 Differential Gear Oil s A INSPECTION sang 1 Set vehicle on a lift 2 Disconnect ground terminal from battery 3 Lift vehicle 4 Disconnect oil temperature sensor connector Turbo model for Europe S3M0615A A Connector 5 Take out filler plug and replace gear oil if it is contaminated or deteriorated Ref to DI P2 REPLACEMENT Differential Gear Oil 6 Check gear oil level is up to the bottom part of filler bolt If the level is low refill up to the bottom of filler bolt x 53 0527 A Filler plug B Drain plug B REPLACEMENT 1 Disconnect ground terminal from battery 2 Jack up vehicle and support it with sturdy racks 3 Disconnect oil temperature sensor connector Turbo model for Europe S3M0615A A Connector
48. owards toe under no load rotation When loaded contact pattern moves toward heel Toe side A Heel side G3M0098A Face contact Backlash is too large This may cause noise and chipping at tooth ends G3M0098B Increase thickness of drive pinion height adjusting washer in order to bring drive pinion closer to crown gear center G3M0098F Flank contact Backlash is too small This may cause noise and stepped wear on surfaces G3M0098C Reduce thickness of drive pinion height adjusting washer in order to move drive pinion away from crown gear 4 G3M0098G Toe contact Contact area is small This may cause chipping at toe ends G3M0098D Adjust as for flank contact 4 G3M0098G Heel contact R Adjusting direction of drive pinion Adjusting direction of crown gear Contact area is small This may cause chipping at heel ends G3M0098E DI 56 Adjust as for face contact G3M0098F REAR DIFFERENTIAL FOR VA TYPE 21 Install rear cover and tighten bolts to specified torque Tightening torque 25 2 5 kgf m 18 1 ft lb S3M0526A A Rear cover E INSPECTION S303151A10 Wash all the disassembled parts clean and exam ine them for wear damage or other defects Repair or replace defective parts as necessary 1 Crown gear and drive pinion e f abnormal tooth contact is evident find out the cause and adjust to give correct tooth c
49. ped side bearing Readjust Replace Replace Vibrating differential carrier DI 67 Replace GENERAL DIAGNOSTIC TABLE Differentials MEMO DI 68
50. porting cone with ST NOTE Place the replacer so that its center recessed side faces the pinion gear ST 498515500 REPLACER S3M0512A 18 Remove front oil seal from differential carrier using ST ST 398527700 PULLER ASSY A L TT N B S3M0513A A Differential carrier B Front oil seal 19 Remove pilot bearing together with front bear ing cone using ST ST 398467700 DRIFT B A S3M0514A A Pilot bearing B Front bearing C Rear bearing cup 20 When replacing bearings tap front bearing cup and rear bearing cup in this order out of case by using a brass bar S3M0515A 2 cutouts along diagonal lines B Tap alternately with brass bar D S ASS EM B LY 303151A02 1 Precautions for assembling e Assemble in the reverse order of disassembling e Check and adjust each part during assembly e Keep the shims and washers in order so that they are not misinstalled e Thoroughly clean the surfaces on which the shims washers and bearings are to be installed e Apply gear oil when installing the bearings and thrust washers e Be careful not to mix up the right and left hand races of the bearings e Replace the oil seal with new one at every dis assembly Apply chassis grease between the lips when installing the oil seal G3M0079 2 Adjust preload for front and rear bearings Adjust the bearing preload with spacer a
51. ps NOTE ST 498447120 OIL SEAL INSTALLER e Apply gear oil on both sides of the washer and on the side gear shaft before installing e Insert the pinion mate shaft into the differential case by aligning the lock pin holes Se Q0 G3M0087 SRY 9 Press fit companion flange with ST1 and ST2 E 8 CAUTION Be careful not to damage bearing ST1 899874100 INSTALLER ST2 399780104 WEIGHT G3M0089 S3M0521A 10 Install self locking nut Then tighten it with ST ST 398427200 FLANGE WRENCH Tightening torque 188 19 2 kgf m 139 ft lb G3M0721 DI 51 REAR DIFFERENTIAL FOR VA TYPE Differentials 1 Measure the side gear backlash 12 Press side bearing cone onto differential case Side gear back clearance with ST 0 05 0 15 mm 0 0020 0 0059 in ST 498485400 DRIFT B3M1933 G3M0091 13 Assemble holders 1 Install oil seal into right and left holders ST 498447100 INSTALLER 2 Adjust the side gear backlash as specified by selecting side gear thrust washer Thickness mm in 0 925 0 950 0 0364 0 0374 0 950 0 975 0 0374 0 0384 0 975 1 000 0 0384 0 0394 1 000 1 025 0 0394 0 0404 1 025 1 050 0 0404 0 0413 3 Check the condition of rotation after apply ing oil to the gear tooth surfaces and thrust sur faces S3M0522A 4 After dr
52. rential parking brake cable guide from the trailing link by using ST CAUTION When removing the DOJ from the rear differential fit ST to the bolt as shown in figure so as not to damage the side bearing retainer ST 208099PA100 DRIVE SHAFT REMOVER H3M1399B A ABS sensor cable clamp B Parking brake cable guide 4 Remove the rear stabilizer link Y sl Z pg ee p CA m Y ET S3M0528 5 Remove the bolts which secure the trailing H3M1667C link to the rear housing A Bolt B DOJ 10 Secure rear drive shaft to rear crossmember using wire G3M0042 6 Remove the bolts which secure the front and rear lateral link to the rear housing S3M0500 SEDED E ed Cl ke 2 G3M0043 DI 64 REAR DIFFERENTIAL SIDE OIL SEAL 11 Remove side oil seal with ST ST 398527700 PULLER ASSY G3M1023 12 Drive in a new side oil seal with ST CAUTION Apply chassis grease between the oil seal lips ST 398437700 DRIFT G3M1024 13 Insert the DOJ into rear differential 1 Install ST to rear differential ST 28099PA090 SIDE OIL SEAL PROTEC TOR G3M1025 Differentials 2 Insert the spline shaft until the spline portion is inside the side oil seal 3 Remove ST ST 28099PA090 SIDE OIL SEAL PROTEC TOR I G3M1026 4 Completely
53. rive pinion nut lock ST1 with ST2 as shown in the figure ST1 398507704 BLOCK ST2 498447150 DUMMY SHAFT Tightening torque 188 N m 19 2 kgf m 139 ft lb G3M1038 Front and rear bearing preload For new bearing 12 7 32 4 N 1 3 3 3 kgf 2 9 7 3 Ib at companion flange bolt hole S3M0517 DI 48 REAR DIFFERENTIAL FOR VA TYPE Differentials ST3 498505501 DIFFERENTIAL CARRIER GAUGE ST2 ST1 RH N ST3 Part No Thickness mm in 38336AA000 1 500 0 0591 38336AA120 1 513 0 0596 38336AA010 1 525 0 0600 38336AA130 1 538 0 0606 38336AA020 1 550 0 0610 38336AA140 1 563 0 0615 38336AA030 1 575 0 0620 38336AA150 1 588 0 0625 38336AA040 1 600 0 0630 38336AA160 1 613 0 0635 Preload adjusting 38336AA050 1 625 0 0640 a B Les S3M0518A washer 38336AA170 1 638 0 0645 l l la l la la 2 5 5 la Ne 38336AA060 1 650 0 0650 A Pinion height adjusting shim 38336AA180 1 663 0 0655 2 Measure the clearance N between the end 38336AA070 1 675 0 0659 of ST3 and the end surface of ST1 by using a 38336AA190 1 688 0 0665 thickness gauge 38336AA080 1 700 0 0669 NOTE 38336AA200 1 713 0 0674 Make sure there is no clearance between the case 38336AA090 1 725 0 0679 and ST3 ST1 498447150 DUMMY SHAFT ST2 498505501 DIFFERENTIAL CARRIER GAUGE 38336AA100 1 750 0 06
54. t B Rear differential 17 Support rear differential with transmission jack 18 Remove self locking nuts connecting rear dif ferential to rear crossmember B3M0131 Differentials 19 Remove bolts which secure rear differential front member to body 1 Loosen bolt A first then remove bolts B NOTE Support front member with a help of an assistant to prevent it from dropping B3M0657C A Bolt A B Bolt B 2 Remove bolt A 20 While slowly lowering transmission jack move rear differential forward and remove bolts from rear crossmember 21 Remove front member from body G3M0059 B INSTALLATION To install reverse the removal sequence 1 Position front member on body by passing it under parking brake cable and securing to rear differential DI 43 REAR DIFFERENTIAL FOR VA TYPE Differentials NOTE When installing rear differential front member do not confuse the installation sequence of the upper and lower stoppers 2 Install DOJ of rear drive shaft into rear differen tial ST 28099PA090 SIDE OIL SEAL PROTEC TOR G3M0049 3 Install in the reverse order of removal 4 After installation fill differential carrier with gear oil Ref to DI 22 Differential Gear Oil C DISASSEMBLY 5303151 06 detect real cause of trouble inspect the follow ing items before disassembling
55. to replace the air breather cap unless necessary S3M0530A A Air breather cap B Rear cover 4 Remove rear cover by loosening retaining bolts S3M0531A A Rear cover B Differential carrier 5 Make right and left side bearing retainers in order to identify them at reassembly Remove side bearing retainer attaching bolts set ST to differen tial case and extract right and left side bearing retainers with a puller CAUTION Each shim which is installed to adjust the side bearing preload should be kept together with its mating retainer ST 398457700 ATTACHMENT S3M0532A 6 Pull out differential case assembly from differ ential carrier CAUTION Be careful not to hit the teeth against the case S3M0533 01 28 REAR DIFFERENTIAL FOR T TYPE 7 When replacing side bearing pull bearing cup from side bearing retainer using ST ST 398527700 PULLER ASSY S3M0534A 8 Extract bearing cone with ST CAUTION Do not attempt to disassemble the parts unless necessary NOTE e Set puller so that its claws catch the edge of the bearing cone e Never mix up the right and left hand bearing races and cones ST 399527700 PULLER SET G3M0068 9 Remove crown gear by loosening crown gear bolts CAUTION Further disassembling is not allowed S3M0509 Differentials 10 Drive out pinion shaft lock pin fro
56. ur hands because each part on the vehicle is hot after running e Use SUBARU genuine gear oil grease etc or the equivalent Do not mix gear oil grease etc with that of another grade or from other manufacturers e Be sure to tighten fasteners including bolts and nuts to the specified torque e Place shop jacks or safety stands at the speci fied points e Apply gear oil onto sliding or revolution surfaces before installation e Before installing O rings or snap rings apply sufficient amount of gear oil to avoid damage and deformation e Before securing a part on a vise place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vise e Avoid damaging the mating face of the case DI 11 Differentials GENERAL DESCRIPTION D PREPARATION TOOL 1 SPECIAL TOOLS S303001A1701 ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS B3M1893 B3M1894 398477701 398477702 HANDLE Used for installing front and rear bearing cone Used press fitting the bearing cone of differen tial carrier rear B3M1895 B3M1896 398217700 498447120 ATTACHEMENT SET OIL SEAL INSTALLER DI 12 Stand for rear differential carrier disassembly and assembly Used for installing front oil seal ILLUSTRATION GENERAL DESCRIPTION TOOL NUMBER DESCRIPTION Differentials REMARKS B3M1897 B3M1898 498427200 398467700 FLANGE WRENCH
57. with gear oil Ref to DI Differential Gear Oil DI 60 REAR DIFFERENTIAL SIDE OIL SEAL 7 Rear Differential Side Oil Seal sn A INSPECTION 5303137410 Check side oil seal portion for oil leakage if any leak is found replace the side oil seal and inspect propeller shaft B REPLACEMENT 5303137 20 1 D VA TYPE 5303137 2002 1 Set vehicle a lift Disconnect ground terminal from battery Move select lever or gear shift lever to Release the parking brake Loosen both wheel nuts 6 Jack up the vehicle and support it with rigid racks 7 Remove wheels 8 Remove rear exhaust pipe and muffler With OBD Ref to EX SOHC 9 REMOVAL Rear Exhaust Pipe and Ref to EX SOHC 11 REMOVAL Muffler gt Without OBD lt Ref to EX SOHCw oOBD 10 REMOVAL Rear Exhaust Pipe and Ref to EX SOHCw oOBD 12 REMOVAL Muffler gt 9 Remove the DOJ of rear drive shaft from rear differential 1 Remove the ABS sensor cable clamp and parking brake cable guide from bracket 2 3 4 5 H3M1397B A ABS sensor cable clamp B Parking brake cable guide 01 61 Differentials 2 Remove the ABS sensor cable clamp from the trailing link H3M1398 3 Remove the ABS sensor cable clamp and parking brake cable guide from the trailing link H3M1399B A Parking brake cable guide B ABS sensor cable clamp 4 Remove the re

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