Subaru Crosstrek Service Manual: Disassembly

To detect the real cause of trouble, inspect the following items before disassembling.

• Tooth contact and backlash between hypoid driven gear and drive pinion

1. Set the ST on vise and install the differential assembly to ST.

2. Remove the drain plug and filler plug.

3. Remove the rear cover by removing retaining bolts.

NOTE:

Remove it by tapping with a plastic hammer.

4. Remove the stud bolts from rear cover if necessary.

5. Remove the air breather cap.

NOTE:

• Do not attempt to remove the air breather cap unless necessary.

• Whenever the air breather cap is removed, replace it with a new part.

6. Remove the lock plate RH and LH.

7. Remove the side retainer RH and LH with ST.

NOTE:

When keeping the retainers aside, use labels etc. to avoid confusing the left and right.

8. Pull out the differential case assembly from differential carrier.

NOTE:

Be careful not to hit the teeth of hypoid driven gear against the differential carrier.

9. Remove the bearing race from side retainer RH and LH with ST1 and ST2.

10. Remove the oil seal from RH and LH side retainers.

NOTE:

Perform this operation only when changing oil seal.

11. Remove the O-rings.

12. Remove the side bearing cone with ST1 and ST2.

NOTE:

• Do not attempt to disassemble the parts unless necessary.

• Set the puller so that its claws catch the edge of the side bearing cone.

• Store so that the right and left side bearing races and cones are not mixed together.

13. Using the ST, loosen the hypoid driven gear bolt and remove the hypoid driven gear.

14. Remove the spring pin from hypoid driven gear side using ST.

15. Draw out the pinion mate shaft and remove pinion mate gears, side gears and side gear thrust washers.

NOTE:

The gears and washers should be marked with RH or LH, front or rear, or kept separately.

16. Remove the self-locking nut while securing the companion flange with ST.

17. Extract the companion flange with a puller.

18. Press the end of drive pinion shaft using ST and remove the rear bearing cone, pinion height adjusting washer, preload adjusting spacer and washer.

NOTE:

Hold the drive pinion so as not to drop it.

19. Remove the rear bearing cone from drive pinion by supporting the bearing cone with ST.

NOTE:

Place the remover so that its center-recessed side faces the bearing cone.

20. Remove the front oil seal from differential carrier using ST.

21. Remove the pilot bearing together with the front bearing cone and spacer using the ST.

22. When replacing the bearings, tap out the front bearing race and rear bearing race in this order using a brass bar to remove them.

Assembly

Inspection

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