Outback L.L.Bean Edition AWD F6-3.0L (2002)
Differential Output Shaft: Testing and Inspection
INSPECTION
Disassembled parts should be washed clean first and then inspected carefully.
1. Bearings Replace bearings in the following cases:
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Bearings, whose balls, outer races and inner races are broken or rusty.
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Worn bearings
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Bearings that fail to turn smoothly or make abnormal noise when turned after gear oil lubrication.
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The ball bearing on the rear side of the drive pinion shaft should be checked for smooth rotation before the drive pinion assembly is
disassembled. In this case, because a preload is working on the bearing, its rotation feels like it is slightly dragging unlike the other bearings.
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Bearings having other defects
2. Bushing (each gear)
Replace the bushing in the following cases:
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When the sliding surface is damaged or abnormally worn.
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When the inner wall is abnormally worn.
3. Gears
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Replace gears with new ones if their tooth surfaces are broken, damaged, or excessively worn.
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Correct or replace if the cone that contacts the baulk ring is rough or damaged.
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Correct or replace if the inner surface or end face is damaged.
4. Baulk ring
Replace the ring in the following cases:
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When the inner surface and end face are damaged.
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When the ring inner surface is abnormally or partially worn down.
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If the gap between the end faces of the ring and the gear splined part is excessively small when the ring is pressed against the cone.
Clearance (A): 0.5 - 1.0 mm (0.020 - 0.039 inch)
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When the contact surface of the synchronizer ring insert is scored or abnormally worn down.
5. Shifting insert key
Replace the insert if deformed, excessively worn, or defective in any way.
