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Front Differential Drain Plug Torque Specs

17K views 13 replies 6 participants last post by  FlatFourAWD  
#1 ·
The drain plug for the front differential on my 2007 Automatic has started to leak. I’ve got a new OEM drain plug and OEM gasket 803926090. According to the FSM, the torque specs are 32 ft-lb with aluminum gasket and 51 ft-lb with copper gasket. As others I’m sure already know, the OEM gasket is neither, it’s steel.

For others who have already been down this road, have you used the copper gasket specs? Anything else to consider during the drain/fill? I’m also using OEM 75W-90 gear oil.
 
#4 ·
Sorry to jump in when I haven't done this myself but I think the reason why a low torque is used with aluminum is so that the gasket doesn't get split, so unless there's some reason why a steel one would need a low torque I would use 51. Presumably there's no risk of stripping the aluminum threads at this torque so it should be safe.
 
#6 ·
Good point. I just wished that Subaru had revised the FSM when they eliminated both aluminum and copper gaskets and switched to steel. Unlike the oil drain plug crush washer, this “gasket” is solid steel. Kinda like a thicker washer.

When I received it it didn’t look like aluminum or copper so I did the magnet test and it’s absolutely steel. It’s actually almost black in color. I’m assuming it’s some type of rust inhibitor.
 
#5 ·
Ditto re not having done this. But if I can bring other experience to bear, if the copper washer is solid, that would explain the much higher torque. If the "aluminum" washer is really steel, then I might go with 32 since 30.8 is the engine drain pan plug spec with steel washer? The main factor is sufficient "crush" without tearing/deforming the washer/gasket. A magnet would tell you for sure if what you have is steel.
 
#9 ·
I doubt you will get a seal with a flat steel washer unless you use some form of sealant as well.

Aluminium and copper washers seal because they “deform” to the shape of the material they are sealing to.

If it was my vehicle I would definitely be using some type of sealant. My sealant of choice is non-hardening aviation cement. It used to be a Permatex product but I believe it is now made by Loctite.

Seagrass
 
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#10 ·
This is an OEM gasket that was purchased from my local Subaru dealer. How can I verify that this is the correct one?

When I realized that it was steel I had the same concern. It’s not like the oil drain plug steel crush washer since this is solid. Yes, copper and aluminum is softer so it will “form” as it’s torqued.

I wonder if SOA could assist?
 
#13 ·
For what it's worth (@FlatFourAWD ) I've done 3 diff fluid changes and reused the factory steel gaskets every time. No sealant ever used, wiped the gasket before reinstall. No fluid leaks (garage floor clean). The seal is made by the threads being tight as heck and the flat surfaces (diff/undamaged washer/bolt) well mated.

SOA will tell you to use what they sold you or go to a shop.