Subaru Impreza 2.5 L 2004 Bedienungsanleitung

DIFFERENTIALS

DI-2

DIFFERENTIALS

GENERAL DESCRIPTION

1. General Description

A: SPECIFICATIONS

When replacing a rear differential assembly, select the correct one according to the following table.

NOTE:

Using the different rear differential assembly causes the drive line and tires to “drag”or emit abnormal noise

when AWD is selected.

•Identification •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.

MODEL

2.5 L 2.0 L Turbo

AT MT AT MT

Wagon Sedan Wagon Sedan

Rear differential type T-type model without LSD T-type model with LSD

LSD type —Viscous coupling

Identification EH EL EG EH EJ EF

Type of gear Hypoid gear

Gear ratio (Number of gear

teeth) 4.111 (37/9) 4.444 (37/9) 3.900 (39/10) 4.111 (37/9) 3.545 (39/11)

Oil capacity 0.8 2(0.8 US qt, 0.7 Imp qt)

Rear differential gear oil GL-5

MODEL 2.5 L Turbo STi

6MT

Rear differential type T-type model with LSD

LSD type Mechanical

Identification HK

Type of gear Hypoid gear

Gear ratio (Number of gear

teeth) 3.900 (39/10)

Oil capacity 0.9 —1.1 2(1.0 —1.2 US qt,

0.8 —1.0 Imp qt)

Rear differential gear oil GL-5 (For mechanical LSD)

DI-00001

(1) Item

(2) Differential gear oil

(3) API Classification

(4) SAE Viscosity NO. and Application Temperature

MT-00001

(1)

(4)

GL-5

(3)

(2)

( C)

( F)

-30 -26 -15 15

85W

80W

75W -90

25 30-5 0

-22 -15 23 32 8659 775

DI-3

DIFFERENTIALS

GENERAL DESCRIPTION

1. SERVICE DATA

2. ADJUSTING PARTS

•Except STi model

Front and rear bearing preload at companion flange bolt

hole N (kgf, lb)

Except STi

model 18.1 —38.8 (1.8 —4.0, 4.1 —8.7)

STi model 24.1 —38.6 (2.5 —3.9, 5.4 —8.7)

Side gear backlash mm (in) 0.10 —0.20 (0.0039 —0.0079)

Side bearing standard width mm (in) 20.00 (0.7874)

Crown gear to drive pinion backlash mm (in) 0.10 —0.20 (0.0039 —0.0079)

Crown gear runout on its back surface mm (in) Less than 0.05 (0.0020)

Front and rear bearing preload at com-

panion flange bolt hole N (kgf, lb) 18.1 —38.8 (1.8 —4.0, 4.1 —8.7)

Preload adjusting spacer

Part No. Length mm (in)

383695201 56.2 (2.213)

383695202 56.4 (2.220)

383695203 56.6 (2.228)

383695204 56.8 (2.236)

383695205 57.0 (2.244)

383695206 57.2 (2.252)

Preload adjusting washer

Part No. Length mm (in)

383705200 2.59 (0.1020)

383715200 2.57 (0.1012)

383725200 2.55 (0.1004)

383735200 2.53 (0.0996)

383745200 2.51 (0.0988)

383755200 2.49 (0.0980)

383765200 2.47 (0.0972)

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)

DI-4

DIFFERENTIALS

GENERAL DESCRIPTION

•STi model

Pinion height adjusting shim

Part No. Thickness mm (in)

383495200 3.09 (0.1217)

383505200 3.12 (0.1228)

383515200 3.15 (0.1240)

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 (0.1417)

383675200 3.63 (0.1429)

383685200 3.66 (0.1441)

Side gear backlash mm (in) 0.1 —0.2 (0.0039 —0.0079)

Side gear thrust washer

(Model without LSD)

Part No. Thickness mm (in)

383445201 0.75 —0.80 (0.0295 —0.0315)

383445202 0.80 —0.85 (0.0315 —0.0335)

383445203 0.85 —0.90 (0.0335 —0.0354)

Side bearing standard width mm (in) —20.00 (0.7874)

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)

Crown gear to drive pinion

backlash mm (in) Limit

0.10 —0.20 (0.0039 —0.0079)

Crown gear runout on its back

surface mm (in) 0.05 (0.0020)

Front and rear bearing preload at com-

panion flange bolt hole N (kgf, lb) 24.1 —38.6 (2.5 —3.9, 5.4 —8.7)

Preload adjusting spacer

Part No. Length mm (in)

31454AA130 52.2 (2.055)

31454AA140 52.4 (2.063)

31454AA150 52.6 (2.071)

31454AA160 52.8 (2.079)

31454AA170 53.0 (2.087)

31454AA180 53.2 (2.094)

DI-5

DIFFERENTIALS

GENERAL DESCRIPTION

Preload adjusting washer

Part No. Length mm (in)

383705200 2.59 (0.1020)

383715200 2.57 (0.1012)

383725200 2.55 (0.1004)

383735200 2.53 (0.0996)

383745200 2.51 (0.0988)

383755200 2.49 (0.0980)

383765200 2.47 (0.0972)

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)

Pinion height adjusting shim

Part No. Length mm (in)

38336AA230 3.09 (0.1217)

38336AA240 3.12 (0.1228)

38336AA250 3.15 (0.1240)

38336AA260 3.18 (0.1252)

38336AA270 3.21 (0.1264)

38336AA280 3.24 (0.1276)

38336AA290 3.27 (0.1287)

38336AA300 3.30 (0.1299)

38336AA310 3.33 (0.1311)

38336AA320 3.36 (0.1323)

38336AA330 3.39 (0.1335)

38336AA340 3.42 (0.1346)

38336AA350 3.45 (0.1358)

38336AA360 3.48 (0.1370)

38336AA370 3.51 (0.1382)

38336AA380 3.54 (0.1394)

38336AA390 3.57 (0.1406)

38336AA400 3.60 (0.1417)

38336AA410 3.63 (0.1429)

38336AA420 3.66 (0.1441)

Side bearing standard width mm (in) 20.00 (0.7874)

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)

Crown gear to drive pinion

backlash mm (in) Limit

0.10 —0.20 (0.0039 —0.0079)

Crown gear runout on its back

surface mm (in) 0.05 (0.0020)

DI-6

DIFFERENTIALS

GENERAL DESCRIPTION

B: COMPONENT

1. REAR DIFFERENTIAL WITHOUT LSD

(1) Pinion crown gear and drive pin-

ion set

(13) Side bearing (26) Stud bolt

(14) O-ring (27) Oil filler plug

(2) Pinion height adjusting shim (15) Side bearing retainer shim (28) Oil drain plug

(3) Rear bearing (16) Side bearing retainer (29) Rear cover

(4) Bearing preload adjusting spacer (17) Side oil seal (30) Differential case

(5) Bearing preload adjusting washer (18) Side gear thrust washer (31) Gasket

(6) Differential carrier (19) Side gear

(7) Front bearing (20) Pinion mate gear Tightening torque: N·m (kgf-m, ft-lb)

(8) Spacer (21) Pinion mate gear washer T1: 10.3 (1.05, 7.6)

(9) Pilot bearing (22) Pinion shaft lock pin T2: 29 (3.0, 21.7)

(10) Front oil seal (23) Circlip T3: 49 (5.0, 36.2)

(11) Companion flange (24) Pinion mate shaft T4: 105 (10.7, 77.4)

(12) Self-locking nut (25) Air breather cap T5: 181 (18.5, 134)

DI-00260

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

( 7 )

( 8 )

( 9 )

(10)

(11)

(12)

(13)

(14)

(15)

(16)

(17)

(18)

(19)

(20)

(23) (21)

(21)

(22)

(24)

(30) (23)

(25)

(26)

(27)

(28)

(29)

(31)

DI-7

DIFFERENTIALS

GENERAL DESCRIPTION

2. REAR DIFFERENTIAL WITH LSD

(1) Pinion crown gear and drive pin-

ion set

(14) O-ring (25) Oil filler plug (Rear differential oil

temperature switch) (STi model)

(15) Side bearing retainer shim

(2) Pinion height adjusting shim (16) Side bearing retainer (26) Stay ground (STi model)

(3) Rear bearing (17) Side oil seal

(4) Bearing preload adjusting spacer (18) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(5) Bearing preload adjusting washer (19) Differential case (Viscous cou-

pling type) (Except for STi model)

T1: 10.3 (1.05, 7.6)

(6) Differential carrier T2: 29 (3.0, 21.7) (Except for STi

model)

(7) Front bearing Differential case (Mechanical

type) (STi model)

(8) Collar 44 (4.5, 32.5) (STi model)

(9) Pilot bearing (20) Rear cover T3: 49 (5.0, 36.2)

(10) Front oil seal (21) Air breather cap T4: 105 (10.7, 77.4)

(11) Companion flange (22) Stud bolt T5: 181 (18.5, 134)

(12) Self-locking nut (23) Oil filler plug

(13) Side bearing (24) Oil drain plug

DI-00347

(18)

(14)

(5)

(4)

(1)

(19)

(6)

(13)

(16)

(3) (2)

(1)

(17)

(15)

(13)

(16)

(17)

(12) (11)

(10) (9)

(8)

(7)

(14) (15)

(21)

(22)

(23)

(25)

(24)

(20)

(26)

DI-8

DIFFERENTIALS

GENERAL DESCRIPTION

3. REAR DIFFERENTIAL MOUNTING SYSTEM

(1) Differential front member (8) Differential mount bracket Tightening torque: N·m (kgf-m, ft-lb)

(2) Plate (9) Differential mount front cover T1: 20 (2.0, 14.5)

(3) Crossmember T2: 33 (3.4, 24.3)

(4) Differential rear member T3: 65 (6.6, 47.9)

(5) Differential mount lower bracket T4: 70 (7.1, 51.6)

(6) Stopper T5: 90 (9.2, 66.4)

(7) Dynamic damper T6: 100 (10.2, 73.8)

DI-00312

(1)

(7)

(6)

(8)

T2 T6

(9) T1

T6 T2

(8)

(6)

(7)

T5 (5)

(4)

(3)

(2)

DI-9

DIFFERENTIALS

GENERAL DESCRIPTION

C: CAUTION

•Wear working clothing, including a cap, protec-

tive goggles, and protective shoes during opera-

tion.

•Remove contamination including dirt and corro-

sion before removal, installation or disassembly.

•Keep the disassembled parts in order and pro-

tect them from dust or dirt.

•Before removal, installation or disassembly, be

sure to clarify the failure. Avoid unnecessary re-

moval, installation, disassembly, and replacement.

•Be careful not to burn your hands, because each

part on the vehicle is hot after running.

•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.

•Be sure to tighten fasteners including bolts and

nuts to the specified torque.

•Place shop jacks or safety stands at the specified

points.

•Apply gear oil onto sliding or revolution surfaces

before installation.

•Before installing O-rings or snap rings, apply suf-

ficient amount of gear oil to avoid damage and de-

formation.

•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.

•Avoid damaging the mating face of the case.

DI-10

DIFFERENTIALS

GENERAL DESCRIPTION

D: PREPARATION TOOL

1. SPECIAL TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

398477701 HANDLE Used for installing front and rear bearing cone.

398477702 DRIFT Used press-fitting the bearing cone of differential

carrier (rear).

398217700 ATTACHMENT SET Stand for rear differential carrier disassembly

and assembly.

498447120 INSTALLER Used for installing front oil seal.

ST-398477701

ST-398477702

ST-398217700

ST-498447120

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