Front Differential Assembly: Adjustment

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

BEVEL PINION GEAR BACKLASH
1. Disassemble the front differential. See DISASSEMBLY - FRONT DIFFERENTIAL ASSEMBLY .
2. Select a different washer from the table and install. See ASSEMBLY - FRONT DIFFERENTIAL ASSEMBLY .
  
  Fig 1: Washer (38.1 X 50 X T) Chart
3. Adjust until the specified value is obtained.
  Standard backlash: 0.13-0.18 mm (0.0051-0.0071 in)
HYPOID GEAR BACKLASH
Adjust backlash by turning holder in right side case.

ST 499787000 WRENCH ASSY

Fig 2: Adjusting Backlash By Turning Holder In Right Side Case

NOTE: Each time holder rotates one tooth, backlash changes by 0.05 mm (0.12 in).

Fig 3: Illustrating Hypoid Gear Backlash Adjustment Increments
TOOTH CONTACT OF HYPOID GEAR
Adjust until the teeth contact is correct.
- Backlash is excessive.
  To reduce backlash, loosen holder on the upper side (case right side) and turn in the holder on the lower side (case left side) by the same amount.
  
  Fig 4: Making Adjustments Until Teeth Contact Is Correct (Excessive Backlash Shown)
- Backlash is insufficient.
  To increase backlash, loosen holder on the lower side (case left side) and turn in the holder on the upper side (case right side) by the same amount.
  
  Fig 5: Making Adjustments Until Teeth Contact Is Correct (Insufficient Backlash Shown)
- The drive pinion shim selected before is too thick.
  Reduce its thickness.
  
  Fig 6: Illustrating Drive Pinion Shim Selected Before Is Too Thick
- The drive pinion shim selected before is too thin.
  Increase its thickness.
  
  Fig 7: Illustrating Drive Pinion Shim Selected Before Is Too Thin