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
   Specifications
   The mechanism of blocking of inclusion of a reverse gear - the device and the principle of functioning
   Interaxal differential - the device and the principle of functioning
   Removal and installation of transmission assembly
   Check of a state and replacement of elements of support of a suspension bracket of transmission assembly
   Check of a state and replacement of an epiploon
   Removal, installation and check of a condition of sensors switches
   Removal, installation and check of a condition of the sensor of the speed (VSS)
   Preparation for performance of capital repairs of RKPP
   Removal, service and installation of a transfer case and lengthening of transmission
   Removal, service and installation of the leading gear wheel of the distributing mechanism
   Removal, service and installation of the conducted gear wheel of the distributing mechanism
   Removal, service and installation of interaxal differential
   Removal, service, installation and adjustment of assembly of the mechanism of blocking of inclusion of a reverse gear
   Removal, installation and check of a condition of a case of transmission assembly
   Removal, service, installation and adjustment of primary shaft of RKPP
   Removal, service and installation of an entrance shaft of RKPP (model with an additional two-level reducer)
   Removal, service and installation of assembly of a shaft of the leading gear wheel of the main transfer of the drive of forward wheels
   Removal, service, installation and adjustment of forward differential
   Removal, installation and check of a condition of a gear wheel of the drive of a speedometer
   Removal, installation and adjustment of an intermediate gear wheel of a reverse gear
   Removal, installation, check and adjustment of assembly of gear wheels of a two-level reducer
   Removal, check of a state and installation of forks and rods of gear shifting
   Removal, service and installation of the lever of gear shifting of RKPP
   Removal, service and installation of the lever of switching of the Hi/Lo modes of an additional two-level reducer
   Removal, service and installation of hummock draft of the drive of switching of the modes of a two-level reducer
+ Automatic transmission
+ Coupling
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment




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Manual box and differential

General information

The scheme of an arrangement of transmission in a motive compartment

1 — the Jet bar
2 — the Rubber pillow

3 — the Cross beam
4 — the Damper of dynamic fluctuations


RKPP design without additional two-level reducer of "H/L"

1 — Primary shaft
2 — the Leading gear wheel of the 3rd transfer
3 — the Leading gear wheel of the 4th transfer
4 — the Leading gear wheel of the 5th transfer
5 — the Transfer case
6 — the Conducted gear wheel of the distributing mechanism
7 — a lengthening Case
8 — the Leading gear wheel of the distributing mechanism

9 — the Viscous coupling
10 — Assembly of interaxal differential
11 — the Conducted (secondary) shaft
12 — the Conducted gear wheel of the 2nd transfer
13 — the Conducted gear wheel of the 1st transfer
14 — the Shaft of the leading gear wheel of the main transfer
15 — Assembly of forward differential


RKPP design with an additional two-level reducer of "H/L"

1 — the Entrance shaft
2 — Assembly of an additional 2-staged reducer of "H/L"
3 — the Leading gear wheel of the 3rd transfer
4 — the Leading gear wheel of the 4th transfer
5 — the Leading gear wheel of the 5th transfer
6 — the Transfer case
7 — the Conducted gear wheel of the distributing mechanism
8 — the lengthening Case
9 — the Leading gear wheel of the distributing mechanism

10 — Assembly of interaxal differential
11 — the Viscous coupling
12 — the Shaft of the leading gear wheel of the main transfer
13 — the Conducted (secondary) shaft
14 — the Conducted gear wheel of the 3rd transfer
15 — the Conducted gear wheel of the 2nd transfer
16 — the Conducted gear wheel of the 1st transfer
17 — the Conducted gear ring of the 1st transfer
18 — Assembly of forward differential


For a complete set of the models of cars considered in the present manual the 5-staged manual box of gear shifting (MBGS), or the 4-staged automatic transmission (AT) are used.

In the present Chapter manual boxes of gear shifting are considered.

In view of complexity of a design of RKPP, absence on free sale of necessary replaceable internal components and need of use of the special equipment, authors of the present manual do not recommend to owners of cars to carry out capital repairs of a transmission independently. Repair of RKPP in the conditions of a workshop of car service is rather expensive operation, in a type of that, it is necessary to consider alternative options of replacement of the failed block new or restored. Any useful information on repair and replacement of transmission can be received at car repair shops of the Subaru company.

Regardless of the chosen way of elimination of problems (repair or replacement), independent dismantle of a box from the car will allow to reduce material inputs significantly. The scheme of installation of transmission in a motive compartment is submitted on an illustration.

RKPP without additional two-level reducer of "H/L"

Design of a 2-staged reducer of "H/L"

1 — the Block of an entrance shaft with an entrance gear wheel of the raising range
2 — the Connecting Hi/Lo coupling
3 — the Intermediate gear wheel

4 — the Entrance gear wheel of the lowering range
5 — Primary shaft of transmission assembly


RKPP without additional two-level reducer of "H/L" has a design with the constant all-wheel drive and unites in itself transmission assembly, forward differential and assembly of a transfer case with interaxal differential. Transmission provides possibility of a choice from five lobbies and one back transfers, reducing couples of each of which are equipped with synchronizers with the inertial sliding keys.

Transmission assembly and forward differential are placed in the two-section aluminum case divided into the left and right half. Behind the cases of a transfer case and lengthening of a check point consolidating the case of a box in whom are concluded part of transmission assembly, the distributing mechanism and interaxal differential settle down.

Gelikoidalny gear wheels of forward transfers differ in the high superficial durability of teeths with the big contact spot of gearing providing a low noise working background.

The choice of a reverse gear is carried out by simultaneous interface of the sliding intermediate gear wheel of a backing to the leading gear wheel of a reverse gear on primary to a shaft and with the conducted gear wheel of the reverse gear equipped with a nave of the synchronizer of switching 1/2 on a shaft of the leading gear wheel of the main transfer.

The interaxal differential provides compensation of a difference of speeds of rotation of forward and back axes and consists of the conic gear wheels and the viscous coupling installed behind placed in the general case. The differential complete with couple of gear wheels of the distributing mechanism provides a torque transmission from transmission on a shaft of the leading gear wheel of the main transfer of a forward axis of the car and on the back driveshaft. The viscous coupling plays a role of an element of management of functioning of differential.

RKPP with an additional two-level reducer of "H/L"

Application in RKPP of a 2-staged reducer of "H/L" established over primary shaft allows to change the general transfer relation of a box by a choice of the raising or lowering mode. Boxes of this kind sometimes call also 10-staged.

 Switching of the modes can be made even at the movement with the squeezed-out coupling pedal.


The design of the main transmission assembly with lengthening, a transfer case, interaxal differential and the main transfer is similar described above for RKPP of usual type (see the previous subsection).

For the purpose of decrease in level of a noise background when switchings coupling the conducted gear wheel of the 1st transfer on a shaft of the leading gear wheel of the main transfer is supplied with an additional gear ring.

In the mode of a vent of the connecting Hi/Lo coupling raising (Hi) are in gearing with vents of the entrance gear wheel of the raising range directly connected to primary shaft and rotating with it with an identical speed. Thus the torque transmission from the engine goes according to the following scheme: an entrance shaft — an entrance gear wheel of the raising range — the connecting Hi/Lo coupling — a nave of the Hi/Lo synchronizer — primary shaft.

In the mode of a vent of the connecting Hi/Lo coupling lowering (Lo) are in gearing with vents of the entrance gear wheel of the lowering range consolidated with primary shaft. Thus the following scheme of a torque transmission is realized: an entrance shaft — an intermediate gear wheel — an entrance gear wheel of the lowering range — the connecting Hi/Lo coupling with a synchronizer nave — primary shaft.