Subaru BRZ 2013 · Service Manual Drive train

Rear differential carrier ASSY

Components Removal / installation

AXLE / DIFFERENTIAL
REAR DIFFERENTIAL CARRIER ASSY
EXPLODED VIEW
REMOVAL
1. Draining of differential oil
(1) Remove the filler plug and the gasket.
(2) Remove the drain plug and the gasket, and then drain oil.
2. Removal of propeller shaft with center bearing ASSY
(Refer to )
3. Removal of differential carrier ASSY RR
(1) Using a tall transmission jack, support the differential carrier ASSY RR.
WARNING:
·The differential carrier ASSY RR is heavy. Be sure to support it with a tall transmission jack.
·In order to prevent the differential carrier ASSY RR from being excessively tilted or coming off, perform the operation while holding it with several assistants.
(2) Remove 5 bolts, and then remove the rear differential mount stopper UPR and the rear differential mount stopper LWR.
(3) Lower the tall transmission jack slowly. Using a tire lever, etc., detach the rear drive shaft ASSY from the differential carrier ASSY RR as shown in the figure.
CAUTION:
If a tire lever, etc. contacts the rear cover, the cover may be damaged. A tire lever, etc. is allowed to contact the differential carrier.
(4) Lower the tall transmission jack. Pull out the rear drive shaft ASSY from the differential carrier ASSY RR, and then remove the differential carrier ASSY RR.
NOTE:
Suspend the detached rear drive shaft ASSY using a string, etc.
DISASSEMBLY
1. Fixation of rear differential carrier ASSY RR
(1) Install the rear differential carrier to the overhaul stand.
2. Removal of rear differential breather plug
(1) Remove the differential breather plug from the differential carrier.
3. Removal of rear differential carrier cover
(1) Remove the 8 bolts.
(2) Using a plastic hammer, lightly tap the rib portion of the differential carrier cover, and remove it from the differential carrier.
CAUTION:
Be careful not to damage the mating surface of the differential carrier.
4. Removal of rear differential breather plug oil deflector
(1) Remove the bolts, and then remove the breather plug oil deflector from the differential carrier cover.
5. Inspection of differential ring gear runout
(1) Inspect the runout of the ring gear by contacting a dial gauge at a right angle to the back surface of the ring gear.
Limit :  0.07 mm {0.003 in}
NOTE:
If it exceeds the limit, remove the ring gear and inspect runout of the differential case.
6. Inspection of backlash between differential ring gear and differential drive pinion
(1) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(2) Secure the companion flange RR by hand, and inspect the ring gear backlash.
Standard value :  0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
Measure at 3 points or more on the ring gear circumference.
7. Inspection of tooth contact between differential ring gear and differential drive pinion
(1) Apply a thin uniform coat of red lead on both teeth surfaces of the ring gear.
(2) Rotate the companion flange RR forward and backward several times.
8. Inspection of differential side gear backlash
(1) Contact a dial gauge at a right angle to the tooth surface end of the differential side gear.
(2) Secure the differential pinion to the differential case side, and then check that the backlash of differential side gear is 0 mm {0 in}.
10. Inspection of differential drive pinion preload
(1) Using a socket wrench (30 mm) and a torque wrench, check preload of the drive pinion within the ring gear backlash.

Standard value:
Tightening torque=1.11 to 1.91N·m { 11.3 to 19.5kgf·cm} {0.82 to 1.41 ft·lbf}
11. Inspection of overall preload
(1) Using a socket wrench (30 mm) and a torque wrench, check overall preload with the drive pinion contacting the ring gear tooth surface.

Standard value:
Tightening torque=1.6 to 2.69N·m { 16.3 to 27.4kgf·cm} {1.18 to 1.98 ft·lbf}
12. Removal of rear differential side gear shaft oil seal
(1) Using a flat tip screwdriver, remove the right and left side oil seals from the differential carrier.
15. Removal of rear differential dust deflector
NOTE:
Perform the operation only when the dust deflector is damaged.
(1) Using the SST and a press, remove the dust deflector from the companion flange RR.
SST     09950-00020  499877000
CAUTION:
Be careful not to drop the companion flange RR.
NOTE:
In order to ensure the contact surface between the SST and the dust deflector, perform the operation while tightening the nut of the SST.
17. Removal of rear differential drive pinion oil slinger
(1) Using a magnet hand, remove the oil slinger from the differential carrier.
18. Removal of rear drive pinion tapered roller bearing FR
(1) Using the SST, remove the tapered roller bearing FR (inner race) from the differential carrier.
SST     09556-22010
Captions in illustration
*a
Drive
*b
Hold
NOTE:
Apply grease to the thread and end portions of the SST center bolt before using it.
19. Removal of rear differential drive pinion bearing spacer
(1) Remove the bearing spacer from the drive pinion.
26. Inspection of differential side gear backlash
(1) Using aluminum plates in between, secure the differential case in a vise.
CAUTION:
Do not vise excessively.
(2) Contact a dial gauge at a right angle to the tooth surface end of the differential side gear, secure the differential pinion gear to the differential case, and then check that the backlash is 0 mm {0 in}.
NOTE:
If the backlash is not 0 mm {0 in}, replace the differential case ASSY.
ASSEMBLY
1. Installation of differential ring gear
2. Installation of rear differential case bearing
(1) Using the SST and a press, press-fit the case bearings (inner race LH and RH) into the differential case.
SST     09710-30012 09710-04081)  398477702
NOTE:
·Press until the case bearing is in close contact with the differential case.
·Align the SST in the center of the differential case.
CAUTION:
·When using new bearings, do not apply differential gear oil.
·Be careful not to deform the cage of the bearing.
·When replacing the bearing, replace the outer race and the inner race as a set.
3. Inspection of differential ring gear runout
(1) Install the case bearing (outer race LH and RH) to the case bearing (inner race LH and RH), and install the differential case to the carrier.
CAUTION:
·When installing the bearing outer races, do not confuse the left and right.
·When using new bearings, do not apply differential gear oil.
(4) Contact a dial gauge at a right angle to the back surface of the ring gear.
(5) Check for runout of the ring gear.
Limit :  0.07 mm {0.003 in}
(8) Remove the differential case and right and left case bearings from the differential carrier.
CAUTION:
Be careful not to damage the differential case bearing and the ring gear.
6. Installation of rear differential dust deflector
(1) Using the SST and a press, press-fit a new dust deflector into the companion flange RR.
SST     499277200  499225500
CAUTION:
·When press-fitting, gradually insert the dust deflector while checking the condition.
·Do not press-fit excessively.
·Remove a burr if it occurs when press-fitting.
7. Adjustment of differential drive pinion preload
(1) While supporting the drive pinion by hand, install the drive pinion tapered roller bearing FR (inner race) to the differential carrier.
CAUTION:
·Be careful not to drop the drive pinion.
·In order to check the tooth contact of the ring gear, install the spacer and oil seal after checking and adjusting the tooth contact.
·When using new bearings, do not apply differential gear oil.
(2) Install the oil slinger to the differential carrier.
(5) Using a socket wrench (30 mm) and a torque wrench, gradually tighten a new drive pinion nut to the specified preload.
Limit :  T = 338 N·m {3447 kgf·cm} {249.3 ft·lbf}
WARNING:
During operation, support the overhaul stand.
CAUTION:
Note that no bearing spacer is inserted. Therefore, tighten the nut gradually. Never overtighten it.
NOTE:
·Tighten to approx. 100 N·m {1020 kgf·cm} {73.8 ft·lbf} while checking the preload.
·Apply differential gear oil to the thread portions of the nut and the drive pinion.
(6) Turn it forward and backward several times to seat the bearing properly.
9. Inspection and adjustment of backlash between differential ring gear and differential drive pinion
(1) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(2) Secure the companion flange RR by hand, and inspect the ring gear by moving it.
Standard value :  0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
·Inspect at 3 points or more on the ring gear circumference.
·Record the measured value for reference when selecting the side gear shaft washer.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
(3) Select the side gear shaft washer which allows the ring gear’s backlash to be within the standard value, and install it to the back face side of the ring gear.
Type of rear differential side gear shaft washer
Thickness (mm {in})
Identification mark
Thickness (mm {in})
Identification mark
2.57 to 2.59 {0.1012 to 0.1020}
01
3.03 to 3.05 {0.1193 to 0.1201}
47
2.59 to 2.61 {0.1020 to 0.1028}
32
3.05 to 3.07 {0.1201 to 0.1209}
17
2.61 to 2.63 {0.1028 to 0.10315}
33
3.07 to 3.09 {0.1209 to 0.1217}
48
2.63 to 2.65 {0.1035 to 0.1043}
03
3.09 to 3.11 {0.1217 to 0.1224}
49
2.65 to 2.67 {0.1043 to 0.1051}
34
3.11 to 3.13 {0.1224 to 0.1232}
19
2.67 to 2.69 {0.1051 to 0.1059}
35
3.13 to 3.15 {0.1232 to 0.1240}
50
2.69 to 2.71 {0.1059 to 0.1067}
05
3.15 to 3.17 {0.1240 to 0.1248}
51
2.71 to 2.73 {0.1067 to 0.1075}
36
3.17 to 3.19 {0.1248 to 0.1256}
21
2.73 to 2.75 {0.1075 to 0.1083}
37
3.19 to 3.21 {0.1256 to 0.1264}
52
2.75 to 2.77 {0.1083 to 0.1091}
07
3.21 to 3.23 {0.1264 to 0.1272}
53
2.77 to 2.79 {0.1091 to 0.1098}
38
3.23 to 3.25 {0.1272 to 0.1280}
23
2.79 to 2.81 {0.1098 to 0.1106}
39
3.25 to 3.27 {0.1280 to 0.1287}
54
2.81 to 2.83 {0.1106 to 0.1114}
09
3.27 to 3.29 {0.1287 to 0.1295}
55
2.83 to 2.85 {0.1114 to 0.1122}
40
3.29 to 3.31 {0.1295 to 0.1303}
25
2.85 to 2.87 {0.1122 to 0.1130}
41
3.31 to 3.33 {0.1303 to 0.1311}
56
2.87 to 2.89 {0.1130 to 0.1138}
11
3.33 to 3.35 {0.1311 to 0.1319}
57
2.89 to 2.91 {0.1138 to 0.1146}
42
3.35 to 3.37 {0.1319 to 0.1327}
27
2.91 to 2.93 {0.1146 to 0.1154}
43
3.37 to 3.39 {0.1327 to 0.1335}
58
2.93 to 2.95 {0.1154 to 0.1161}
13
3.39 to 3.41 {0.1335 to 0.1343}
59
2.95 to 2.97 {0.1161 to 0.1169}
44
3.41 to 3.43 {0.1343 to 0.1350}
29
2.97 to 2.99 {0.1169 to 0.1177}
45
3.43 to 3.45 {0.1350 to 0.1358}
60
2.99 to 3.01 {0.1177 to 0.1185}
15
3.45 to 3.47 {0.1358 to 0.1366}
61
3.01 to 3.03 {0.1185 to 0.1193}
46
3.47 to 3.49 {0.1366 to 0.1374}
31
(4) Using a plastic hammer, lightly tap the differential carrier for better fitting of the case bearing and the side gear shaft washer.
(5) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(6) Secure the companion flange RR by hand, and inspect the backlash by moving the ring gear.
Standard value :  0.13 to 0.18 mm {0.005 to 0.007 in}
(7) If out of the standard, select the side gear shaft washer which allows the ring gear’s backlash to be around the standard value, and install it to the back face side of the ring gear.
(9) Using a plastic hammer, lightly tap the differential carrier for better fitting of the case bearing.
(10) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(11) Secure the companion flange RR by hand, and inspect the backlash by moving the ring gear.
Standard value :  0.13 to 0.18 mm {0.005 to 0.007 in}
(12) If out of the standard, adjust the thickness of the right and left side gear shaft washers, increasing or decreasing by the same amount.
NOTE:
·Record the measured value for reference when selecting the side gear shaft washer.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
10. Inspection and adjustment of differential case bearing preload
(1) After adjusting the backlash of the ring gear, remove the side gear shaft washer on the tooth face side of the ring gear.
(2) Using a micrometer, inspect the thickness of the side gear shaft washer.
(3) Select the side gear shaft washer that is 0.06 to 0.09 mm {0.002 to 0.004 in} thicker than the removed side gear shaft washer.
CAUTION:
Install the side gear shaft washer that can be inserted into about two thirds of the way using a finger.
(4) Using the SST and a hammer, press-fit the side gear shaft washers into the differential carrier.
SST     09504-22012
(6) Using 4 bolts, tighten the right and left bearing caps.

Standard value:
Tightening torque=85N·m { 867kgf·cm} {62.7ft·lbf}
CAUTION:
The bearing cap and the carrier are manufactured as a unit; do not change the combination.
(7) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(8) Secure the companion flange RR by hand, and inspect the backlash by moving the ring gear.
Standard value :  0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
·Measure at 3 points or more on the ring gear circumference.
·If any small backlash is found, replace the side gear shaft washer on the tooth face side of the ring gear with a thicker one.
·Record the measured value for reference when selecting the side gear shaft washer.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
·When adjusting the backlash, bring the average value close to 0.1 mm {0.004 in}.
11. Inspection and adjustment of overall preload
(2) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(3) Secure the companion flange RR by hand, and inspect the backlash by moving the ring gear.
Standard value :  0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
·Measure at 3 points or more on the ring gear circumference.
·If the backlash is out of the standard, adjust the thickness of the right and left side gear shaft washers, increasing or decreasing by the same amount.
·When adjusting the backlash, bring the average value close to 0.1 mm {0.004 in}.
·If any small backlash is found, replace the side gear shaft washer on the tooth face side of the ring gear with a thicker one.
·Record the measured value for reference when selecting the side gear shaft washer.
·For reference when selecting the side gear shaft washer, inspect the tooth contact between the differential ring gear and the drive pinion.
(4) Recheck the overall preload.
12. Inspection of tooth contact between differential ring gear and differential drive pinion
(1) Apply a thin uniform coat of red lead on both teeth surfaces of the ring gear.
(2) Rotate the companion flange forward and backward several times.
15. Removal of rear differential drive pinion oil slinger (Refer to )
16. Removal of rear drive pinion tapered roller bearing FR (Refer to )
17. Installation of rear differential drive pinion bearing spacer
(1) Install a new bearing spacer to the drive pinion.
CAUTION:
Install the part with a larger inner diameter to the drive pinion side, and the part with a smaller to the companion flange RR side.
18. Installation of rear drive pinion tapered roller bearing FR
(1) Install the tapered roller bearing FR (inner race) to the differential carrier.
19. Installation of rear differential drive pinion oil slinger
(1) Install the oil slinger to the differential carrier.
20. Installation of rear drive pinion companion flange RR
(1) Using the SST and the companion flange RR, press-fit the tapered roller bearing RR (inner race) into the differential carrier.
SST     09950-30012 09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03030)
Captions in illustration
*a
Drive
*b
Hold
NOTE:
·Apply grease to the thread and end portions of the SST center bolt (09953-03010) before using it.
·The bolts and nuts used for securing the SST and the companion flange RR are recommended to be M8 × P1.25 with a bolt length of approx. 40 mm {1.6 in}.
22. Installation of rear differential carrier oil seal (Refer to )
26. Inspection of backlash between differential ring gear and differential drive pinion
(1) Contact a dial gauge at a right angle to the tooth surface end of the ring gear.
(2) Secure the companion flange RR by hand, and inspect the ring gear backlash.
Standard value :  0.13 to 0.18 mm {0.005 to 0.007 in}
NOTE:
Measure at 3 points or more on the ring gear circumference.
28. Fixation of rear drive pinion nut
(1) Crimp the drive pinion nut using a chisel and a hammer.
30. Installation of rear differential drain plug
(1) Install the drain plug to the differential carrier through a new gasket using a socket hexagon wrench 10.

Standard value:
Tightening torque=49N·m { 500kgf·cm} {36.1ft·lbf}
31. Installation of rear differential breather plug oil deflector
(1) Using a scraper and a wire brush, clean the seal gasket that is attached to the differential carrier and the carrier cover, and then degrease it with a cleaning solvent, etc.
CAUTION:
Be careful not to damage the mating surface of the differential carrier.
(2) Using bolts, install the breather plug oil deflector to the differential carrier cover.

Standard value:
Tightening torque=8.0N·m { 82kgf·cm} {5.9ft·lbf}
33. Installation of rear differential breather plug
(1) Install the differential breather plug to the differential carrier.

Standard value:
Tightening torque=21N·m { 214kgf·cm} {15.5ft·lbf}
34. Removal of rear differential carrier ASSY RR
(1) Remove the rear differential carrier ASSY RR from the overhaul stand.