Subaru Legacy (2005 year). Service manual - part 742

DI-75

DIFFERENTIALS

Rear Differential Front Member

8. Rear Differential Front Mem-

ber

A: REMOVAL

1) Disconnect the ground cable from battery.
2) Lift-up the vehicle.
3) Support the rear differential using transmission
jack, and then remove the rear differential front
member.

B: INSTALLATION

Install the rear differential front member with a new
self-locking nut.

Tightening torque:

T1: 52 N

⋅

m (5.3 kgf-m, 38 ft-lb)

T2: 110 N

⋅

m (11.2 kgf-m, 81 ft-lb)

C: INSPECTION

1) Check the rear differential front member for
damage, bend and corrosion.
If damage, bend or corrosion is excessive, replace
the rear differential front member. 
2) Check the bushings of rear differential member
for cracking, hardening and damage.
If cracking, hardening or damage is excessive, re-
place rear differential front member.

(A) Rear differential front member

DI-00293

(A)

DI-00294

T2

T1

DI-76

DIFFERENTIALS

General Diagnostic Table

9. General Diagnostic Table

A: INSPECTION

Symptom or trouble

Possible cause

Remedy

1. Oil leakage

(1) Worn, scratched or incorrectly seated 
front or side oil seal. Scored, battered or 
excessively worn sliding surface of com-
panion flange.

Correct or replace.

(2) Clogged or damaged air breather.

Clean, repair or replace.

(3) Loose bolts on differential spindle or 
side retainer, or incorrectly fitted O-ring.

Tighten the bolts to specified torque. 
Replace the O-ring.

(4) Loose rear cover attaching bolts or 
damaged gasket.

Tighten the bolts to specified torque. 
Replace gasket and apply liquid gasket.

(5) Loose oil filler or drain plug.

Retighten and apply liquid gasket.

(6) Wear, damage or incorrectly fitting for 
spindle, side retainer and oil seal.

Correct or replace.

2. Seizure
NOTE:
Seized or damaged parts should be re-
placed, and also other parts should be
thoroughly checked for any defect and
should be repaired or replaced as re-
quired.

(1) Insufficient backlash for hypoid gear.

Readjust or replace.

(2) Excessive preload for side, rear or 
front bearing.

Readjust or replace.

(3) Insufficient or improper oil used.

Replace seized part and fill with specified 
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 re-
paired or replaced as required.

(1) Improper backlash for hypoid gear.

Replace.

(2) Insufficient or excessive preload for 
side, rear or front bearing.

Readjust or replace.

(3) Excessive backlash for differential 
gear.

Replace gear or thrust washer.

(4) Loose bolts and nuts such as hypoid 
driven gear bolt.

Retightening.

(5) Damage due to overloading.

Replace.

4. Noises when starting or shifting 
gears
NOTE:
Noises may be caused by differential as-
sembly, universal joint, wheel bearing,
etc. Find out what is actually making noise
before disassembling.

(1) Excessive backlash for hypoid gear.

Readjust.

(2) Excessive backlash for differential 
gear.

Replace gear or thrust washer.

(3) Insufficient preload for front or rear 
bearing.

Readjust.

(4) Loose drive pinion nut.

Tighten to specified torque.

(5) Loose bolts and nuts such as side 
bearing retainer attaching bolt.

Tighten to specified torque.

5. Noises when cornering

(1) Damaged differential gear.

Replace.

(2) Excessive wear or damage of thrust 
washer.

Replace.

(3) Broken pinion mate shaft.

Replace.

(4) Seized or damaged side bearing.

Replace.

DI-77

DIFFERENTIALS

General Diagnostic Table

6. Gear noise
NOTE:
Since noises from engine, muffler, trans-
mission, 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 coast-
ing, 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, try-
ing to pick up only differential noise.

(1) Improper tooth contact of hypoid gear.

Readjust or replace hypoid gear set.

(2) Improper backlash for hypoid gear.

Readjust.

(3) Scored or chipped teeth of hypoid 
gear.

Replace hypoid gear set.

(4) Seized hypoid gear.

Replace hypoid gear set.

(5) Improper preload for front or rear 
bearings.

Readjust.

(6) Seized, scored or chipped front or 
rear bearing.

Replace.

(7) Seized, scored or chipped side bear-
ing.

Replace.

(8) Vibrating differential carrier.

Replace.

Symptom or trouble

Possible cause

Remedy

DI-78

DIFFERENTIALS

General Diagnostic Table