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99-outback 03-28-2013 12:56 PM

Help with front differential on 99 legacy outback
Hello all,
In the process of removing the drive shaft the stub shaft from the differential pulled out damaging my differential seal. At first I thought it was pulling hard just from being stuck but then it all popped out. Then I went ahead and got a new seal to replace the damaged one. But the problems started when I removed the (outer bearing/seal retainer cap). I did think ahead and mark the cap with paint pen so I could properly tighten it back down, but in the hurried confusion I forgot to remark it after running it threw the parts washer. Thankfully I only did this to one side. The other side i removed with a ground down chisel and broke off one of the nubs i later used this as a reference point because it also was run threw the parts washer. I promptly made a spanner tool that worked much better and did not break any more nubs.

My question is how can I reset the preload on the second cap to the correct spot.

Question number 2: while i had bearing cap out on the passengers side i also pulled the cap from the drivers side witch caused the differential to fall down in its case. I aligned the shaves by eye and put the bearing cap back on. My question to this is: will this be O.K. or damage the differential?

Any help would be very much appreciated, Thanks in advance.

johnegg 03-30-2013 01:59 PM

you are in a pickle.

there is a process for setting the correct position of the front diff . i do not know exactly what it is but it is a bit complicated and involves a bit of trial and error to get just the right position. then after you get it right, you tighten one side and loosen the other a specific n umber of turns.

you only have a few choices, take it to a shop, do the best you can and hope, or replace the trans.

i guess by now you have figured out that you should have
1/ done one side at a time.
2/ counted the number of turns as you removed the cap so you could re-install the exact number to the exact position.

good luck

99-outback 12-23-2013 10:38 PM

all patched up and running great thanks for the help. yes live and learn

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