Subaru Crosstrek Service Manual: Inspection

Wash all the disassembled parts clean, and examine them for wear, damage or other defects. Repair or replace the defective parts as necessary.

1. Hypoid driven gear and drive pinion

• If there is evidently an abnormal tooth contact, find out the cause and adjust until the teeth contact correctly. Replace the gear if there is an excessive worn or an incapable adjustment.

• If crack, cutout or seizure is found, replace the parts as a set. Slight damage of some teeth can be corrected by oil stone or the like.

2. Side gear and pinion mate gear

• Replace if cracks, scoring or other defects are evident on the tooth surface.

• Replace if thrust washer contact surface is worn or seized. Slight damages of the surface can be corrected by oil stones or equivalent.

3. Bearing

Replace if seizure, peeling, wear, rust, dragging during rotation, noise or other defect is evident.

4. Side gear thrust washer

Replace if seized, flawed, abnormally worn or having other defects.

5. Oil seal

Replace if deformed or damaged, and at every disassembling.

6. Differential carrier

Replace if the bearing bores are worn or damaged.

7. Differential case

Replace if its sliding surfaces are abnormally worn, burned, or cracked.

8. Companion flange

Replace if the oil seal lip contact surface shows cracking.

Side gear backlash:

0.05 — 0.15 mm (0.002 — 0.006 in)

Hypoid driven gear backlash:

0.10 — 0.15 mm (0.004 — 0.006 in)

1. If rust or dirt is attached to the companion flange, remove them.

2. Set a dial gauge at a companion flange surface (mating surface of propeller shaft and companion flange), and then measure the companion flange runout.

Limit of runout:

0.08 mm (0.003 in)

3. Set the gauge inside of the companion flange, and measure the runout.

Limit of runout:

0.08 mm (0.003 in)

4. If either runout exceeds the limit, move the phase of companion flange and drive pinion 90° each, and find the point where the runout is within the limit.

5. If the runout exceeds the limit even after changing the phase, replace the companion flange and recheck the runout.

6. If the runout exceeds the limit after replacing the companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.

Disassembly

Installation

Other materials:

Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Drive Pinion Shaft AssemblyASSEMBLY1. Install the sleeve and the gear and hub assembly by matching the alignment marks.NOTE:• Make sure that there is no large clearance at both sides of the 1st-2nd shifting insert after assembly.(A)1st-2nd shiftin ...

Inspection
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO) > EGR Control ValveINSPECTION1. Check that the EGR control valve has no deformation, cracks or other damages.2. Measure the resistance between EGR control valve terminals.Terminal No.Standard2 and 122±2 ?2 and 322±2 ?5 and 422±2 ?5 and 622 ...

Headlights (models with HID headlights)
WARNING High-intensity-discharge (HID) bulbs are used for the low beams of the headlights. These HID bulbs use an extremely high voltage. To avoid the risk of an electric shock that could result in serious injury, observe the following precautions. Do not replace any headlight bulbs (bo ...