Drive Pinion Shaft: Adjustment

WARNING: This page is about a different car, the 2003 Subaru Outback, 2003 Subaru Legacy, and 2003 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.

Thoroughly remove the liquid gasket from the case mating surface beforehand.
Install the oil pump housing assembly to the torque converter clutch case, and secure evenly by tightening four bolts.
NOTE: Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing.
1. Tightening torque: 41 N.m (4.2 kgf-m, 30A ft-lb)
Fig 1: Installing Oil Pump Housing Assembly To Torque Converter Clutch Case
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Rotate the drive pinion several times with ST1 and ST2.
1. ST1 498937110 HOLDER
2. ST2 499787700 WRENCH
Fig 2: Rotating Drive Pinion Several Times
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Adjust the backlash between drive pinion and crown gear. < Ref. to ADJUSTMENT , Front Differentials.>
Apply red lead evenly to the surfaces of three or four teeth of the crown gear. Rotate the drive pinion in the forward and reverse directions several times.
Then remove the oil pump housing, and check the tooth contact pattern.

If tooth contact is improper, readjust the backlash or shim thickness. < Ref. to ADJUSTMENT , Front Differentials.>
- Tooth contact
Checking item: Tooth contact pattern is slightly shifted toward to toe side under no-load rotation. [When loaded, contact pattern moves toward heel.]

Fig 3: Identifying Tooth Contact Pattern
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- Face contact
Checking item: Backlash is too large.

Contact pattern

Fig 4: Identifying Face Contact Pattern
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Corrective action: Increase thickness of drive pinion height adjusting shim in order to bring drive pinion close to crown gear.

Fig 5: Increasing Thickness Of Drive Pinion Height Adjusting Shim
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- Flank contact
Checking item: Backlash is too small.

Contact pattern

Fig 6: Identifying Flank Contact Pattern
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Corrective action: Reduce thickness of drive pinion height adjusting shim in order to move drive pinion away from crown gear.

Fig 7: Reducing Thickness Of Drive Pinion Height Adjusting Shim
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- Toe contact (Inside end contact)
Checking item: Contact areas is small.

Contact pattern

Fig 8: Identifying Toe Contact Pattern
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Corrective action: Decrease thickness of drive pinion height adjusting shim in order to move drive pinion away from crown gear.

Fig 9: Decreasing Thickness Of Drive Pinion Height Adjusting Shim
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- Heel contact (Outside end contact)
Checking item: Contact areas is small.

Contact pattern

Fig 10: Identifying Heel Contact Pattern
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Corrective action: Increase thickness of drive pinion height adjusting shim in order to move drive pinion close to crown gear.

Fig 11: Increasing Thickness Of Drive Pinion Height Adjusting Shim
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If tooth contact is correct, mark the retainer position and loosen it. After fitting a new O-ring and oil seal, screw in the retainer to the marked position. Then tighten the lock plate to the specified torque.
1. Tightening torque: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
Fig 12: Tightening Lock Plate To Specified Torque
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