Center differential fail.

Earlier this month my sister was driving my car, she called me complaining about a clunking noise coming from the front passenger when making left turns. I told her to just take her time n get it home, assuming it was a CV the right axle. Get another phone call saying she stalled out and claimed it was binding and wouldn't move, including a snap.

 

Got it towed home, and it couldn't even roll up the driveway without binding again. A little rocking and a snap was heard but it was put into the garage and on jacks.

 

-Little bit of grease leak from the passenger CV but there is no play

-Rear had trouble engaging without assistance (pulling driveshaft toward front)

-ball joints, tie rods, and axles show no other leaks

 

Transmission was dropped and opened on the center dif end and it was found that the snap ring and gasket fell off of the viscous unit and binded between gears in the transfer unit.

 

Looking to replace center viscous unit and input shaft inside the transfer case. Subaru quoted 1107.23 for the following

-center viscous unit/center differential assembly

-gear-transfer driveshaft

-2 roller bearings

 

I'd prefer a used set but I'm having trouble finding them. Repairing the dif would be idea as well but the subaru tech said the manual doesn't allow them to repair, saying they would just replace it. Also having trouble finding a diff repair shop. It seems inevitable to purchase a new input shaft.

 

Any suggestions? Pictures to follow soon.

 

 

Here are some useful references I found as well.

http://opposedforces.com/parts/legacy/us_b13/type_7/manual_transmission/

http://legacygt.com/forums/showthread.php/installing-hexmods-center-differential-bulletproof-bushings-164597.html?t=164597&highlight=center+differential

http://www.subaruforester.org/vbulletin/f89/center-diffs-how-replace-them-46979/

Transmission and transfer case opened and laid out.

http://farm9.staticflickr.com/8491/8345197470_d7268564c8_m.jpg

http://farm9.staticflickr.com/8075/8344136295_552e29a4a6_m.jpg

 

Transfer case input shaft, center diff, and snap ring.

http://farm9.staticflickr.com/8073/8345195136_059230c026_m.jpg

http://farm9.staticflickr.com/8080/8344136721_5424921693_m.jpg

http://farm9.staticflickr.com/8221/8344136537_c74c36430b_m.jpg

http://farm9.staticflickr.com/8083/8345194940_cf5f8d945c_m.jpg

 

Rough looking gear oil

http://farm9.staticflickr.com/8081/8345195364_5767bd5139_m.jpg

Car currently has about 137k miles, 2nd gear failed at around 60k and was replaced with an oem clutch.

That gear you show in the picture looks to have a piece of a corner taken off, do you think that might've caused the binding and clanging?

 

My rear diff on my '96 Legacy is making the same noise, and the tires 'stick' and then 'release' when turning (even a little bit) on dry pavement.

no, because once that snap ring comes off the fluid inside the viscous couplings comes out and that is what causes the binding.

 

if i remember correctly from my research, you can replace the viscous couplings on the older models, check with your local dealer to see if they can get them for you.

 

on our newer models you have to buy the whole assembly. i was curious as to why and took my ruined center differential apart and it was impossible to put the viscous couplings back.

 

OP how much is the input shaft shaft from the dealer? Your quote seems high unless that shaft is like 200$. if you can get some form of discount i got my center differential for 450$ +$100 for bearings.

Off the top of my head, the viscous unit is 647, the shaft just over 350 and the two roller bearings for the shaft are 97 in total. This is kerbeck subaru of Atlantic city's price. The salesman said I have until Monday to order it since that's when he'll send his orders out.

 

The snap ring came out of the differential, the subaru mechanic had to look it up and find that it was part of it. It wasn't intact with the dif at all. I assumed it was a washer against the unit itself prior. Even the mechanic was confused for a bit

Just has a similar problem. Retaining ring completely came off the VC and destroyed the drive and driven gears on my daughter's car.

 

http://i349.photobucket.com/albums/q390/meenaveen/Subaru%20VC/IMG_4285_zps04ac9e42.jpg

 

http://i349.photobucket.com/albums/q390/meenaveen/Subaru%20VC/IMG_4293_zps783b11c4.jpg

 

Is this common? This is an image I pulled off the web.

 

http://i349.photobucket.com/albums/q390/meenaveen/Subaru%20VC/OldStyleFromWeb_zps384ef8a5.jpg"]http://i349.photobucket.com/albums/q390/meenaveen/Subaru%20VC/OldStyleFromWeb_zps384ef8a5.jpg[/url]

 

New VC has a fairly thick circlip retaining the VC plate.

 

http://i349.photobucket.com/albums/q390/meenaveen/Subaru%20VC/IMG_4272_zps06097653.jpg