Outback Differential in 1st gen Legacy

[Svengouli7]

I'm sure this has been done 1000x but I thought I would share here for future reference. I just got done installing a rear diff from a 97 or 98 lego outback (on my 92 legacy), with female inputs for the axles. I was able to use the stock rear axles with the stubs removed from the original diff and pinned in place. I did not have the correct socket for the stubs but managed to get the star head bolt out with a 8mm 1/4" drive deep socket without drama or harm. The outback axles are a touch longer and I did not try installing them, I looked at swapping the inner cups but the dimensions of the 2 axles are different in regards to the bearing cage as well as thickness of the shafts (old ones where thicker).

 

Next issue was the pinion flange, the bolt pattern varies- I happened to have the donor driveline and simply used just the rear potion (diff to carrier bearing) otherwise one would have to try to swap the flanges- and I have no idea if the inner dimensions would interchange as far as pressing into the front pinion bearing.

 

I went through all this since my bearings in the unit were TOAST- bad rattle noise that appeared @45mph and increased in frequency with more speed, letting off the gas would get you a nice death rattle noise before quieting down.

 

Super stoked to get this sorted out- I had rebuilt the 4eat last year after losing reverse and had been worried this noise was something I had done wrong- driving it the sound seemed everywhere. Putting it up on stands and disconnecting the rear narrowed it down.

 

Glad to have my mountain car back!

[86BRATMAN]

All the subaru r160 pinion flanges will swap. I've done it a few times over the years in similar situations.

[Svengouli7]

What's your method for holding the pinion flange in order to break the nut loose?

[86BRATMAN]

An impact is the most effective way get it off.