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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Specifications

General information

Gear shifting box

Type

5-staged, or 5 ÷ 2-staged (with an additional 2-staged reducer), synchronized

Type of transmission oil

GL-5

Volume of transmission oil, l

Models without additional 2-staged reducer

3.5

Models with an additional 2-staged reducer

4.0

Transfer relations

1st transfer

3.454:1

2nd transfer

2.062:1

3rd transfer

1.448:1

4th transfer

1.088:1

5th transfer

0.825:1

Reverse gear

3.333:1

The transfer relations of an additional two-level reducer (at the corresponding complete set)

The raising mode

1.000:1

The lowering mode

  • Models of 2.0 l
1.447:1
  • Models of 2.5 l
1.196:1

Main transfer of the drive of forward wheels

Type

Gipoidny

Transfer relation

Models of 2.0 l

3.900:1

Models of 2.5 l

Legacy

3.700:1

Outback

3.900:1

Transfer case

Type

Gelikoidalny

Transfer relation

1.100:1

Main transfer of the drive of back wheels

Type

Gipoidny

Transfer relation

Models of 2.0 l

3.900:1

Models of 2.5 l

Legacy

3.700:1

Outback

3900:1

Forward differential

Type of gear wheels

Conic, pryamozuby

Quantity of gear wheels

The lateral

2

Satellites

2

Interaxal differential

Type

With the viscous coupling

Type of gear wheels

Conic, pryamozuby

Quantity of gear wheels

The lateral

2

Satellites

2

Adjusting parameters

 Adjusting data are provided also in the text of the Head.

Assembly of RKPP

Gap of gearing of a gipoidny leading gear wheel, mm

Nominal rate

0.13 ÷ 0.18

The list of the let-out adjusting washers

detail No.
322295 AA031
322295 AA071
322295 AA041
322295 AA081
322295 AA051
322295 AA091
322295 AA061
322295 AA101

Thickness
0.150
0.250
0.175
0.275
0.200
0.300
0.225
0.500

The list of the let-out back plates of primary shaft

Size "A", mm

detail No.
Marking

4.00 ÷ 4.13

32294AA041
1

3.87 ÷ 3.99

32294AA051
2

Gap between a lock ring and a persistent washer, mm

Nominal rate

0.05 ÷ 0.35

The list of the let-out lock rings (external-19)

detail No.

Thickness, mm

031319000

1.50

805019010

1.72

Adjustment of the holder of an entrance shaft

D size, mm
52.50 ÷ 53.11
52.00 ÷ 52.49
51.26 ÷ 51.99

Quantity of washers

1
2

Assembly of the leading gear wheel

Pretightness of the persistent bearing, Nanometer

Nominal rate

0.3 ÷ 0.8

The list of the let-out adjusting washers

detail No.

Thickness, mm

Washer No. 1

803025051 3.925
803025052 3.950
803025053 4.975
803025054 4.000
803025055 4.025
803025056 4.050

803025057

4.075
Washer No. 2
803025059 3.850
803025054 4.000

803025058

4.150

Moment of resistance to a provorachivaniye of the ball bearing of the leading gear wheel, Nanometer

0.1 ÷ 1.5

Assembly of an entrance shaft

Gap between a lock ring (external-28) and the ball bearing, mm

Nominal rate

0 ÷ 0.12

The list of the let-out lock rings

detail No.

Thickness, mm

805028050

2.48

805028060

2.56

805028070

2.64

Gap between a lock ring (external-68) and the ball bearing, mm

Nominal rate

0 ÷ 0.12

The list of the let-out lock rings

detail No.

Thickness, mm

805168020

1.84
805168030
1.92
805168040
2.00

Assembly of primary shaft

Gap between a lock ring (external-25) and a nave of the synchronizer, mm

Nominal rate

0.060 ÷ 0.100

The list of the let-out lock rings

detail No. Thickness, mm
805025051 — 2.42
805025055 — 2.62
805025052 — 2.47
805025056 — 2.67
805025053 — 2.52
805025057 — 2.72
805025054 — 2.57
805025058 — 2.37

Intermediate gear wheel of a reverse gear

Gap between a gear wheel and the left wall of a case of transmission, mm

Before installation of the lever

Nominal rate

6.0 ÷ 7.5

The list of the released switching levers

detail No.

Marking
Remarks

32820AA070

7
Farther from a wall

32820AA080

8
Face value

32820AA090

9
Closer to a wall

After installation of the lever

Nominal rate

0 ÷ 0.5

The list of the let-out washers

detail No.
803020151
803020154
803020152
803020155
803020153

Thickness, mm
0.4
1.9
1.1
2.3
1.5

Switching forks with rods

Forks are selected so that the connecting coupling and the conducted gear wheel of a reverse gear appeared on the center of the synchronizing mechanisms.

Axial side play of rods, mm

А:

1-2 ÷ 3-4 0.4 ÷ 1.4

В:

3-4 ÷ 5 0.5 ÷ 1.3

The list of the let-out forks

Transfer case

Adjustment of neutral situation

The list of the let-out adjusting washers

detail No.

Thickness, mm

32190AA000
32190AA010

0.15
0.30

Lengthening assembly

Gap between a persistent washer (50 x 61 x t) and an external holder of the conic roller bearing, mm

Nominal rate

0.2 ÷ 0.3 mm (in a tightness)

The list of the let-out persistent washers

detail No.

Thickness, mm

803050060

0.50

803050061

0.55

803050062

0.60

803050063

0.65

803050064

0.70

803050065

0.75

803050066

0.80

803050067

0.85

803050068

0.90

803050069

0.95

803050070

1.00

803050071

1.05

803050072

1.10

803050073

1.15

803050074

1.20

803050075

1.25

803050076

1.30

803050077

1.35

803050078

1.40

803050079

1.45

Gap between a persistent washer and interaxal differential, mm

Nominal rate

0.15 ÷ 0.35 mm (T)

The list of the let-out persistent washers

detail No.

Thickness, mm

803036050

0.9

803036054

1.0

803036051

1.1

803036055

1.2

803036052

1.3

803036056

1.4

803036053

1.5

803036057

1.6

803036058

1.7

Forward differential

Side play of gearing of lateral gear wheels with satellites, mm

Nominal rate

0.13 ÷ 0.18

The list let out washers (38.1 x 50 x t)

detail No.
803038021
803038023
803038022

Thickness, mm
0.925 ÷ 0.950
1.025 ÷ 1.050
0.975 ÷ 1.000

Gap between an axis of satellites and a power shaft, mm

Nominal rate

0 ÷ 0.2

The list of the let-out lock rings (external-28)

detail No.

Thickness, mm

805028011
805028012

1.05
1.20

Leading gear wheel of the distributing mechanism

Gap between a lock ring (external-30) and the ball bearing

Nominal rate

0.01 ÷ 0.15

The list of the let-out lock rings

detail No.

Thickness, mm

805030041

1.53

805030042

1.65

805030043

1.77

Efforts of a tightening of threaded connections, Nanometer

Efforts of a tightening of threaded connections are given also in the text of the Head and on sopr. illustrations.

Bolts of fastening of transmission to a damper of dynamic fluctuations

35

Bolts of fastening of a back cross beam of transmission

70

Bolts of fastening of a forward cross beam of transmission

140

Bolts/nut of fastening of the central beam of transmission

70

Bolts/nut of fastening of a pillow of a back support of a suspension bracket of transmission

35

Bolts of fastening of the limiter of raskachivaniye of the power unit

From the engine

50

From a body

58

Bolts/nut of fastening of transmission to the engine

50

Transmission grounding tire plug

13

Drain stopper of a case of RKPP

44

Sensor switch of fires of a backing

24.5

Nuts of fastening of the HI/LO sensor switch (box with a two-level reducer)

24.5

Sensor of speed of the car (VSS)

5.9

Bolt of fastening of the directing supply of oil to a case of a transfer case

6.4

Sensor switch of neutral situation RKPP

10

Bolts of fastening of a case of a transfer case to a transmission case

25

Bolts of fastening of the case of lengthening to a case of a transfer case

40

Bolts of fastening of an arm of the mechanism of switching

25

Bolts of fastening of the ball bearing of the leading gear wheel of the distributing mechanism

26

Bolts of fastening of a sleeve of the mechanism of blocking of inclusion of a reverse gear

6.4

Cap of a nest of landing of a lock ball of the mechanism of blocking of inclusion of a reverse gear

10

Bolts of fastening of the holder of an entrance shaft (box with a two-level reducer)

20

The sensor switch of activation of the lowering mode (a box with a two-level reducer)

25

Bolt of a fork of switching of the HI/LO modes (box with a two-level reducer)

15.7

Coupling bolts of a case of RKPP with a two-level reducer

25

Lock-nut of primary shaft of transmission

118

Lock-nut of a secondary shaft

118

Lock-nut of the leading gear wheel

265

Bolts of fastening of lock plates of holders of forward power shafts in a differential box

25

Bolts of fastening of the koronchaty conducted gear wheel of forward differential

62

Bolts of fastening of a plate of the basis of the lever of gear shifting

7.5

Nut of fastening of a rod of gear shifting to the gear shifting lever

12

Nut of fastening of a rod of gear shifting to the hinge

18

Bolts of fastening of a rubber support of the mechanism of gear shifting

18

Gear shifting mechanism arm nut

18

Traffic jams of control balls of rods of forks of gear shifting

19.6