Subaru Legacy/Outback

1999-2003 of release

Repair and operation of the car



Subaru of Legasi, Autbek
+ Cars Subaru Legacy, Outback
+ Operation manual
+ Routine maintenance
+ Engine
+ Cooling systems, heating
+ Power supply system and release
+ Electric equipment of the engine
+ Manual box and differential
+ Automatic transmission
- Coupling
   Specifications
   + Flywheel and coupling
   - Driving and cardan shaft, back differential
      The drive of forward wheels - the general information
      Removal and installation of rotary fists, service of stupichny assemblies of forward wheels
      Removal, service and installation of a forward power shaft
      The drive of back wheels - the general information
      Removal and installation of stupichny assemblies of back wheels, replacement of the back stupichny bearing
      Removal, check of a state and installation of components of the driveshaft
      Check of a state and replacement of a forward epiploon of back differential
      Removal, service, installation and adjustment of back differential of T-type
      Removal, service, installation and adjustment of back differential of VA type
      Removal, installation and check of a condition of a forward beam of fastening of back differential
      Removal, service and installation of a back power shaft
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment









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Removal, service, installation and adjustment of back differential of T-type

REMOVAL

Design of back differential

A — Lateral gear wheels
B — Satellites
With — the Persistent washer

D — a differential Box
E — the Axis of satellites


 PERFORMANCE ORDER

1. Disconnect a negative cable from the battery.
2. Install the AT selector lever in the situation "N"/include neutral transfer (RKPP)
3. Give wheel nuts.
4. Release the parking brake.
5. The car also establish to Poddomkratta it on props.
6. Remove wheels.
7. Remove back section of system of production of the fulfilled gases with the muffler (see the Head of the Power supply system and release).
8. Uncover the thermofilter (see the Head of the Power supply system and release).
9. Remove the driveshaft (see the Section Removal, check of a state and installation of components of the driveshaft).
10. Prepare a transmission jack and fixing belts.

11. Release samokontryashchiyesya nuts of fastening of back differential to a back beam.

12. By means of a stripper of ST 28099PA100 release the CV JOINT of a back power shaft from back differential.

Bolte's A

13. Give nuts of protection of differential.

14. Remove a forward beam of back differential and prop up back differential a transmission jack.

15. Belts rigidly fix back differential on a jack.
16. Give samokontryashchiyesya nuts of fastening of back differential to a cross beam.
17. Having accurately chosen a suitable corner and the provision of a transmission jack and its support, turn out a carving hairpin of back differential from the plug of a cross beam.
18. Lower a support of a transmission jack, - try not to hook a power shaft about a bolt of the cross lever.
19. If did not make it yet, release back power shafts from differential, - in case of need use ST 28099PA100 stripper.
20. Lower a transmission jack.
21. Tie up back power shafts to cross levers of a back suspension bracket.

22. Remove protection and a fixing plate of back differential.

A — Protection
B — the Fixing plate

DISMANTLING

Removal of the directing bearing

A — the Bearing of the leading gear wheel
B — the Forward bearing

With — the Cup of the back bearing


Adjustment of a pretightness of forward and back bearings of differential

A — the Washer of adjustment of height of a gear wheel
B — Prostavka of adjustment of a pretightness
With — the Washer of adjustment of a pretightness

ST1 — the False shaft
ST2 — the False plug


 PERFORMANCE ORDER

1. For the purpose of definition by truth of a cause of defect, before dismantling of back differential check spots of contact and a side play of gearing of teeths of koronchaty and leading gear wheels of differential, measure the size of a beating koronchaty and resistance to rotation of the leader of gear wheels.
2. Clamp in a vice the holder of ST 398217700 and fix on it assembly of back differential.
3. Merge oil from differential.

4. Uncover a sapuna, - replacement of a cover has to be made only in case of the valid need.

A — the Cover of a sapun
B — the Back cover of a case of differential


5. Release fixing bolts and remove a back cover of a case of differential, - in case of need tap a cover a hammer with soft the brisk.

6. Mark adjusting provisions of holders of the right and left lateral bearings. Turn out fixing bolts, establish a stripper of ST 398457700 on the differential case and with its help remove holders, - all adjusting washers have to develop together with the corresponding holder.

7. Take a differential box from a case, - try not to damage gear wheel teeths.

8. Remove sealing rings and epiploons from holders of lateral bearings, - at assembly all sealing elements are subject to replacement without fail.

9. In case of need replacements of lateral bearings, use ST 398527700 stripper for removal of their cups.

10. By means of the same stripper remove cones of bearings.

 Do not disassemble bearings needlessly, all removed components at assembly have to be established strictly on the former places.

11. Turn out fixing bolts and remove the koronchaty conducted differential gear wheel.

 Further dismantling is not allowed.


12. Raschekante and by means of a stripper of ST 899904100 take a koronchaty gear wheel a lock pin of an axis of satellites (model without LSD).
13. Take an axis and gear wheels of satellites, lateral gear wheels and persistent washers (models without LSD).

 Do not mix the left, right, forward and back gear wheels.

14. Holding a connecting flange ST 498427200 key, release a nut of the leading gear wheel, then by means of a stripper dismantle a connecting flange.
15. By means of a drift of ST 398467700 wring out the end of a shaft of the leading gear wheel and take it together with a cone of the back bearing, a pro-rate of adjustment of a pretightness and a washer.

16. Having recorded a cone of the back bearing by means of the ST 398517700 adaptation, remove it from a shaft of the leading gear wheel.

17. By means of a stripper of ST 398527700 take an epiploon from a differential box.
18. By means of a drift of ST 398467700 remove the directing bearing together with a cone of the forward bearing.

19. In need of replacement of bearings beat out from a box of differential of their cup, - use a brass drift.

And — Two diagonalno located a groove
In — the Brass drift

20. Carefully wash out all removed components and examine them. Replace defective details.
21. Check a condition of lateral gear wheels and satellites, - at detection of cracks or zadir, and also at excessive wear contact surfaces of persistent washers replace the corresponding components. Insignificant defects of teeths can be eliminated with the help an oselka.
22. Check bearings for existence of signs of jamming, wear, corrosion, estimate the level of the noise background published at rotation. Replace defective components.
23. Check a condition of persistent washers of lateral gear wheels and satellites. Replace the worn-out and damaged components.
24. Replace all sealing elements.
25. Estimate a differential case condition, in case of identification of signs of excessive wear of nests under installation of bearings, cracks and other mechanical damages make replacement.
26. The box of differential is subject to replacement at identification of signs of excessive wear, cracks and other mechanical damages.
27. Check a condition of the surfaces of a connecting flange contacting to an epiploon, in case of detection of defects the flange is subject to replacement.

Assembly and adjustment

 PERFORMANCE ORDER

 All sealing elements (rings and epiploons at assembly are subject to replacement without fail! Do not forget to grease sealing sponges of epiploons at installation.

1. Assembly is made as it should be, the return to an order of dismantle of components. During assembly check a condition of all established components, make necessary adjustments. Try not to mix an order of installation of washers and adjusting plates.

 Carefully wipe persistent washers, adjusting plates and components of bearings before installation and oil the transmission. Try not to mix holders of the right and left bearings.


2. Adjust a pretightness of forward and back bearings by selection of the remote pro-rates and washers established between them.

 Thickness of a washer of adjustment of height of the leading gear wheel does not render on this adjustment of influence. Adjustment has to be moved at the removed epiploon.

a) By means of the ST1 398477701 handle and a mandrel/drift of ST2 398477703 press a holder of the back bearing in a differential box;
b) Fill in a differential box a false shock shaft of ST1 398507702 with put on it by a washer of adjustment of height of the leading gear wheel and a new cone of the back bearing.

 If the washer is not deformed, it can be reused;

c) Establish a remote pro-rate and a washer of adjustment of a pretightness of the bearing, a cone of the forward bearing, the false ST2 398507703 plug, a connecting flange, a washer and a nut of the leading gear wheel;
d) For shrinkage of components turn a false shaft manually of ST1 398507704, then start tightening the NEW nut of the leading gear wheel, measuring thus the size of a pretightness of bearings. Pick up such adjusting pro-rate and a washer that at the nut tightened with the demanded effort (181 Nanometer) the pretightness conformed to the requirements listed in the table given below.

 Use a new lock-nut. Do not exceed the upper bound of nominal range of a pretightness (19.6 ÷ 28.4 N: for the new bearing and 8.34 ÷ 16.67 N: for the bearing which was in the use). At a tightening of a nut of the leading gear wheel block a false shaft from a provorachivaniye by means of ST2 398507704 stopper.

The list of the let-out pro-rates and washers of adjustment of a pretightness of forward and back bearings of back differential of T-type
Washer detail No.  Thickness, mm
  383705200 2.59
  383715200 2.57
  383725200 2.55
  383735200 2.53
  383745200 2.51
  383755200 2.49
  383765200 2.47
  383775200 2.45
  383785200 2.43
  383795200 2.41
  383805200 2.39
  383815200 2.37
  383825200 2.35
  383835200 2.33
  383845200 2.31
Pro-rate detail No.  Thickness, mm
  383695201 56.2
  383695202 56.4
  383695203 56.6
  383695204 56.8
  383695205 57.0
  383695206 57.2

3. Adjust height of the conducting gear wheel by selection of the washer established between its back wall and a cone of the back bearing.

a) Establish a false shaft of ST1 398507702, the measuring instrument of a case of differential of ST2 398507701 and the false ST3 398507703 plug and make the demanded effort of a pretightness (19.6 ÷ 28.4 N: for the new bearing and 8.34 ÷ 16.67 N: for the bearing which was in the use) to forward and back bearings.

 At the same time establish temporarily picked up adjusting washer, previously having measured and having written down its thickness;

b) Measure by the probe of lezviyny type N gap between the measuring instrument and an end face of a false shaft, - track that the gap between the measuring instrument and a box of differential was completely chosen;
c) Using a formula T = T0 + N– – (Hkh0.01) – 0.20 (where T0 = Thickness of the temporary established washer, T = the Demanded thickness of an adjusting washer, N = the Indication of the measuring instrument, N = Numerical marking on a head of the leading gear wheel) and the data given below pick up an adjusting washer of the demanded thickness and establish it instead of temporarily established. For example, let: T0 = 2.20 + 1.20 = 3.40 mm, N = 0.23 mm, H = + 1, then: T = 3.40 + 0.23 – 0.01 – 0.20 = 3.42 it is also necessary to establish an adjusting washer No. 383605200.

The list of the let-out washers of adjustment of height of the leading gear wheel of back differential of T-type

detail No. Thickness, mm
383495200 3.09
383505200 3.12
383515200 3.15
383525200 3.18
383535200 3.21
383545200  3.24
383555200 3.27
383565200 3.30
383575200 3.33
383585200 3.36
383595200 3.39
383605200 3.42
383615200 3.45
383625200 3.48
383635200 3.51
383645200 3.54
383655200 3.57
383665200 3.60
383675200 3.63
383695200 3.66

4. By means of a mandrel of ST 398177700 press a cone of the back bearing on the place.
5. Fill the leading gear wheel, in a differential case, establish a podobrannyeprostavka and a washer of adjustment of a pretightness of forward and back bearings in advance.

6. By means of the false ST1 398507703 plug, freight of ST2 399780104 and a mandrel of ST3 899580100 press a cone of the forward bearing in a case.

7. Establish a pro-rate then by means of freight of ST1 399780104 and a mandrel of ST2 899580100 press the directing bearing.
8. By means of a mandrel of ST 498447120 put the NEW epiploon in a differential case, having filled it on depth of 1 mm, - do not forget to grease an epiploon sponge before installation.
9. By means of a mandrel of ST1 899874100 and freight of ST2 399780104 press a connecting flange.
10. By means of a key of ST 498427200 tighten with the demanded effort (181 Nanometer) NEW samokontryashchuyusya a nut.
11. Establish in a differential box lateral gear wheels and satellites with persistent washers, fill an axis of satellites.

 Before installation both parties of washers and a pin lateral a gear wheel should be oiled the transmission.


12. Measure the size of a side play of gearing of lateral gear wheels and adjust it by selection of the corresponding persistent washers.

The list let out persistent washers of adjustment of a side play of gearing of lateral gear wheels (T-type differential)

detail No. Thickness, mm
383445201 0.75 ÷ 0.80
383445202 0.80 ÷ 0.85
383445203 0.85 ÷ 0.90
383445204 0.90 ÷ 0.95
383445205 0.95 ÷ 1.00

13. Grease teeths and persistent surfaces of lateral gear wheels with transmission oil and check freedom of their rotation.
14. Fill a pin of blocking of an axis of satellites in a differential box and fuller it from both parties.
15. Establish a koronchaty leading gear wheel on a differential box.

 Before a vvorachivaniye of bolts grease their carving part with the fixing sealant like Three Bond 1324. A tightening of fixing bolts with the demanded effort (103 Nanometers) make in a diagonal order, periodically tapping on their heads.

16. By means of a mandrel of ST 398487700 press a cone of the lateral bearing in a differential box.

 When replacing a cone replace as well a bearing cup.

17. Put a cup of the lateral bearing in the holder, - try not to scratch working surfaces of components.

 Assembly of the bearing is replaced complete with a cone.

18. By means of a mandrel press in the holder of the lateral bearing the NEW epiploon, previously slightly oil the interfaced surfaces of components the transmission.
19. Establish the NEW sealing ring on the holder of the lateral bearing.
20. The side play of gearing of the conducted gear wheel and a pretightness of lateral bearings are defined by selection of adjusting washers of holders of lateral bearings.
21. Fill a differential box in a case, - act as it should be, the return to an extraction order.
22. Establish adjusting washers of holders of lateral bearings and sealing rings in holders from whom they were removed (do not mix!).

 Replace the burst or sealing rings, also replace the adjusting washers broken or damaged by corrosion similar on thickness.

The list of the let-out adjusting washers of holders of lateral bearings (T-type differential)

detail No. Thickness, mm
383475201 0.20
383475202 0.25
383475203 0.30
383475204 0.40
383475205  0.50

23. Achieve combination of the arrows applied on a case of differential and on holders of lateral bearings, - try not to damage rollers external holders of lateral bearings.
24. Tighten bolts of holders of lateral bearings with the demanded effort (10.3 Nanometers), previously having greased their carving part with the fixing sealant like Three Bond 1105.

25. Measure the size of a side play of gearing of a koronchaty wheel with the leading gear wheel.

26. Measure resistance of the leading gear wheel to rotation and compare result of measurement with received at measurement of the same parameter at the removed differential box, - the size of increase in result should not exceed the limit of the range of 2.9 ÷ 10.8 N. In case of need pick up new adjusting washers of holders of lateral bearings and repeat check.
27. Check the size of a beating of a koronchaty gear wheel on its back surface, estimate smoothness of rotation of differential.
28. Check and adjust spots of contact of teeths of a koronchaty gear wheel for what apply an even layer of lead minium on both parties of three-four teeths and start rotating differential until the accurate trace of a spot of contact is formed. In case of need make the corresponding adjustment by repeated adjustment of height of the leading gear wheel, selection of new washers of holders of lateral bearings and adjustment of a side play of gearing.

 Upon termination of adjustment remove minium traces.

29. At impossibility of adjustment or excessive wear replace a koronchaty gear wheel. At identification of signs of jamming, zadir or cracks, replace a koronchaty gear wheel complete with the leader.
30. Check a side play of gearing lateral and koronchaty gear wheels, the size of an axial beating koronchaty gear wheels and the size of a full pretightness of bearings. In case of need make the corresponding adjustments.
31. Establish a back cover and tighten bolts of its fastening with the demanded effort (29 Nanometers).


Treatment of results of check of spots of contact of teeths of koronchaty and leading gear wheels of differential

Direction of adjustment of the leading gear wheel

Direction of adjustment of a koronchaty gear wheel


Options of a form and arrangement of spots of contact of teeths

Condition
Contact spot
Adjustment
Correct gearing
The contact spot at rotation without loading is slightly displaced to a sock, - in the presence of loading the spot is displaced to a heel
Superficial gearing
The gearing side play is excessively great

Can lead to increase of level of a noise background and a skalyvaniye of the ends of teeths


Increase thickness of laying of adjustment of height of the leading gear wheel to approach it to an axis of a koronchaty gear wheel
Lateral gearing
The side play of gearing is insufficient

Can cause to lead to increase of level of a noise background and premature wear of working surfaces of teeths

Reduce thickness of laying of adjustment of height of the leading gear wheel to remove it from an axis of a koronchaty gear wheel
Shift to a sock
The area of a spot of contact is insufficient

Can lead to a skalyvaniye of teeths from socks

Adjust, as in a case with lateral gearing
It is displaced to a heel
The area of a spot of contact is insufficient

Can lead to a skalyvaniye of teeths from heels

Adjust, as in a case with superficial gearing

INSTALLATION

 PERFORMANCE ORDER

1. Establish protection and a fixing plate of back differential.
2. Establish back differential on a transmission jack and fasten them with bandage tapes.

3. Establish ST 28099PA090 epiploon protector on back differential.

4. Fill a power shaft in differential, having passed its shlitsevy part in an epiploon, then remove a protector.
5. Pressing back differential, completely fill in it power shafts.
6. Having chosen the suitable provision of a transmission jack, fill a carving hairpin of back differential in the plug of a back cross beam.
7. Lift a jack and temporarily tighten samokontryashchiyesya nuts of a back cross beam.
8. Further installation is made as it should be, the return to an order of dismantle of components, - track that all fixture was tightened with the demanded effort.

9. Having finished installation, fill about 0.8 l of fresh oil in differential, having brought its level to the top mark.

 Before a tightening of a jellied stopper with the demanded effort (49.0 Nanometers), grease its carving part with sealant like Three Bond 1105.


A — the Jellied stopper
B — the Drain stopper