Subaru Legacy/Outback

1999-2003 of release

Repair and operation of the car

Removal, service and installation of a transfer case and lengthening of transmission

Design of the distributing mechanism and lengthening of RKPP

1 — Directing oil supply
2 — Sealing laying
3 — the Case of a transfer case
4 — the Ball
5 — the Spring of the mechanism of blocking of inclusion of a reverse gear
6 — the Sealing washer
7 — the Stopper
8 — the Epiploon
9 — the Internal spring lock ring
10 — the Persistent plate of the blocking mechanism
11 — the Spring of a cam of the blocking mechanism
12 — the Returnable spring of an axis of the blocking mechanism
13 — the Cam of the blocking mechanism
14 — the Axis of a cam of the blocking mechanism
15 — the Cap of a returnable spring of an axis of the blocking mechanism
16 — the Returnable spring of an axis of the blocking mechanism
17 — the Sealing ring
18 — the Adjusting washer
19 — the Sleeve of the blocking mechanism
20 — the Sealing washer
21 — the Sensor switch of neutral provision of transmission
22 — the Sealing washer
23 — the Sensor switch of fires of a backing
24 — the Roller bearing
25 — the Conducted gear wheel of the distributing mechanism

26 — the Roller bearing
27 — the Adjusting washer
28 — the Ball bearing
29 Interaxal differential
30 — the Adjusting washer
31 — the Leading gear wheel of the distributing mechanism
32 — the Ball bearing
33 — the lengthening Case
34 — the Epiploon
35 — the Boot
36 — a switching mechanism Arm
37 — the Spring lock ring

Efforts of a tightening of threaded connections, Nanometer

T1: 6.4
T2: 10
T3: 25
T4: 26
T5: 40

REMOVAL

PERFORMANCE ORDER

1. Remove assembly of RKPP (see the Section Removal and installation of transmission assembly).
2. Remove sensors switches of fires of a backing and the neutral provision of transmission (see the Section Removal, installation and check of a condition of sensors switches).

3. Remove a transfer case assembled with the transmission lengthening case.

4. Remove the executive lever of switching.

5. Remove lengthening assembly.

DISMANTLING

Transfer case

PERFORMANCE ORDER

1. Remove assembly of the mechanism of blocking of inclusion of a reverse gear (see the Section Removal, service, installation and adjustment of assembly of the mechanism of blocking of inclusion of a reverse gear).

2. Remove directing oil supply.

Transmission lengthening

PERFORMANCE ORDER

1. Remove sideways the leading gear wheel of the distributing mechanism (see the Section Removal, service and installation of the leading gear wheel of the distributing mechanism).

2. Remove a switching mechanism arm.

3. Remove an epiploon from the lengthening case.

ASSEMBLY

PERFORMANCE ORDER

Assembly is made as it should be, the return to an order of dismantle of components. Do not forget to replace a transmission lengthening epiploon. Track that all fixture was tightened with the demanded effort (see Specifications and accompanying illustrations to the subsection "Dismantling").

INSTALLATION

PERFORMANCE ORDER

1. If took, establish interaxal differential and the conducted gear wheel of the distributing mechanism in a transfer case.

A — a bearing Cone
B — the lengthening Case

2. Remove a cone of the bearing from assembly of the case of lengthening and put him on the conic roller bearing of the conducted gear wheel of the distributing mechanism.

3. Wringing out a bearing cone in the horizontal direction, 10-multiply turn the conducted shaft.

4. Measure the size of a vystupaniye of the conic roller bearing of the conducted gear wheel of the distributing mechanism over the interfaced surface of a case of a transfer case distance between a transfer case (W).

5. At the removed cones of the bearing and a persistent washer measure depth of "X".

6. On the basis of results of the performed measurements pick up a persistent washer of the demanded thickness (t), - calculation is made on a formula:
t = X – W + (0.2 ÷ 0.3) mm. The nominal size of a gap between a persistent washer and the conical roller bearing makes 0.2 ÷ 0.3 mm. The list of the persistent washers delivered on the market is given below.

Thickness of the let-out persistent washers (50x61xt)

Designation 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

7. Put on persistent washers the leading shaft of the distributing mechanism.
8. Put a bearing cone in the transmission lengthening case.

9. Having used the special conductor of ST 398643600, measure depth of landing of interaxal differential in a case of a transfer case (S).

10. By means of the conductor of ST 398643600 measure depth of landing of the leading gear wheel of the distributing mechanism in the case of lengthening (T).

11. = S + T – 30 mm (the conductor's thickness) pick up thickness of a persistent washer for a formula U. The nominal size of a gap makes 0.15 ÷ 0.35 mm. The list of the washers delivered on the market is given below.

Thickness of the let-out persistent washers

Designation 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

12. Establish a persistent washer on interaxal differential.

13. Apply sealant on the interfaced surface of a transfer case sealant like Three Bond 1215.

14. Press assembly of lengthening to a transfer case and tighten fixing bolts with the demanded effort (40 Nanometers).
15. Install the switching mechanism lever in a transfer case, having hung out it on a rod of a fork of switching 3/4.

16. Establish assembly of a transfer case with lengthening on transmission and tighten fixing bolts with the demanded effort (25 Nanometers).