Rear Differential: Disassembly

WARNING: This page is about a different car, the 2001 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: To detect real cause of trouble, inspect the following items before disassembling. See INSPECTION .

Tooth contact of crown gear and pinion, and backlash
Runout of crown gear at its back surface
Turning resistance of drive pinion

Set ST on vise and install the differential assembly to ST.
ST 398217700 ATTACHMENT

Fig 1: Mounting Differential Assembly On Attachment Plate
Drain gear oil by removing plug.
Remove the air breather cap.
NOTE: Do not attempt to replace the air breather cap unless necessary.

Fig 2: Identifying Air Breather Cap
Remove rear cover by loosening retaining bolts.

Fig 3: Removing Rear Cover
Make right and left side bearing retainers in order to identify them at reassembly. Remove side bearing retainer attaching bolts, set ST to differential 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

Fig 4: Removing Side Bearing Retainer
Pull out differential assembly from differential carrier.
CAUTION: Be careful not to hit the teeth against the case.

Fig 5: Pulling Out Differential Assembly
When replacing side bearing, pull bearing cup from side bearing retainer using ST.
ST 398527700 PULLER ASSEMBLY

Fig 6: Pulling Bearing Cup From Side Bearing Retainer
Extract bearing cone with ST.
CAUTION: Do not attempt to disassemble the parts unless necessary.
NOTE:
- Set puller so that its claw catch the edge of the bearing cone.
- Never mix up the right and left hand bearing cups and cones.
ST 399527700 PULLER SET

Fig 7: Removing Bearing From Differential Assembly
Remove crown gear by loosening crown gear bolts.
CAUTION: Further disassembling is not allowed.

Fig 8: Removing Crown Gear (Ring Gear)
Drive out pinion shaft lock pin from crown gear side. (Without LSD)
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

Fig 9: Driving Out Pinion Shaft Lock Pin From Crown Gear Side
Draw out pinion mate shaft and remove pinion mate gears, side gears and thrust washers. (With-out LSD)
NOTE: The gears as well as thrust washers should be marked or kept separated left and right, and front and rear.

Fig 10: Identifying Differential Assembly Components
Hold companion flange with ST and remove drive pinion nut.
ST 498427200 FLANGE WRENCH

Fig 11: Removing Drive Pinion Nut
Extract the companion flange with a puller.

Fig 12: Removing Companion Flange
Press the end of drive pinion shaft and extract it together with rear bearing cone, preload adjusting spacer and washer.
NOTE: Hold the drive pinion so as not to drop it.

ST 398467700 DRIFT

Fig 13: Pressing Out Drive Pinion Shaft
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 498515500 REPLACER

Fig 14: Removing Rear Bearing Cone From Drive Pinion
Remove front oil seal from differential carrier using ST.
ST 398527700 PULLER ASSY

Fig 15: Removing Front Oil Seal From Differential Carrier
Remove pilot bearing together with front bearing cone using ST.
ST 398467700 DRIFT

Fig 16: Removing Pilot Bearing Together With Front Bearing Cone
When replacing bearings, tap front bearing cup and rear bearing cup in this order out of case by using a brass bar.

Fig 17: Tapping Out Front Bearing Cup