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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Removal, installation and check of a condition of a case of transmission assembly

Design of a case of transmission assembly

1 — a transmission Case
2 — Sealing laying
3 — the Drain stopper
4 — the External spring lock ring
5 — the Conducted speedometer gear wheel
6 — the Washer
7 — a speedometer Shaft
8 — the External spring lock ring
9 — the Epiploon
10 — the Collar
11 — the Arm of the limiter of rocking of the power unit
12 — the Clamp

13 — the Probe of measurement of level of oil
14 — the Sealant (a box with an additional reducer)
15 — a transmission Case (a box with an additional reducer)
16 — the Arm of A driving cables of switching of Hi/Lo (a box with an additional reducer)
17 — the Arm of B driving cables of switching of Hi/Lo (a box with an additional reducer)

Efforts of a tightening of threaded connections, Nanometer

Т: 44


Order and efforts of a tightening of coupling bolts of semi-cases of RKPP

 

 

REMOVAL

Boxes without additional two-level reducer

 PERFORMANCE ORDER

1. Remove assembly of RKPP (see the Section Removal and installation of transmission assembly).
2. Remove a coupling pedal (see the Head Stsepleniye).
3. Remove a transfer case with the lengthening case (see the Section Removal, service and installation of a transfer case and lengthening of transmission).

4. Turn out bolts of fastening of bearings.

5. Remove a back plate of primary shaft.

6. For the purpose of prevention of damage of epiploons wind with an insulating tape of a vent of the drive of the right and left power shafts.

7. Having released coupling bolts and nuts, divide the transmission case into the left and right half.

8. Take assembly of a shaft of the leading gear wheel of the main transfer from the left semi-case of transmission.

 In case of need hook assembly resistant to extraction by the hammer handle.

9. Take assembly of primary shaft.

10. Take assembly of differential. Try not to mix external lock rings of the right and left roller bearings and not to damage the holder's epiploon.


Models with an additional two-level reducer

 PERFORMANCE ORDER

1. Remove assembly of RKPP (see the Section Removal and installation of transmission assembly).
2. Remove a coupling pedal (see the Head Stsepleniye).
3. Remove a transfer case with the lengthening case (see the Section Removal, service and installation of a transfer case and lengthening of transmission).

4. Remove the holder of an entrance shaft.

A Holder of an entrance shaft
B Entrance shaft

5. Remove the sensor switch of the Hi/Lo modes (see the Section Removal, installation and check of a condition of sensors switches).

6. By means of a special drift of ST 398791700 take a fixing pin and remove the executive lever of switching of "Hi/Lo".

A — the Pin
B — the Lever of the Hi/Lo switch

7. Remove a back plate of primary shaft.
8. For the purpose of prevention of damage of epiploons wind with an insulating tape of a vent of the drive of the right and left power shafts.
9. Having released coupling bolts and nuts, divide the transmission case into the left and right half.
10. Take assembly of a shaft of the leading gear wheel of the main transfer from the left semi-case.

At hard landing use, for example, the hammer handle.


11. Having a little raised assembly of primary shaft, remove a fork of the Hi/Lo switch together with its shaft and a washer.

 In case of need hook assembly resistant to extraction by the hammer handle.



A — the Fork of switching of "Hi/Lo"
B — Assembly of an entrance shaft

12. Take assemblies of primary and entrance shaft.

 Entrance and primary shaft separate from each other, - do not drop components!


A — Assembly of primary shaft
B — Assembly of an entrance shaft

13. Take assembly of differential. Try not to mix external lock rings of the right and left roller bearings and not to damage the holder's epiploon.
14. Attentively study both sections of a case on existence of cracks, damages and signs of development of leak of oil.

INSTALLATION

Models without additional two-level reducer

 PERFORMANCE ORDER

1. The rags moistened in gasoline carefully wipe the interfaced surfaces of semi-cases of transmission, having completely removed from them traces of greasing, oil and mud deposits.
2. Establish assembly of forward differential.
3. Establish assembly of primary shaft. Install the needle bearing, having tracked hit of a pin of a case in a reception opening.
4. Establish assembly of a shaft of the leading gear wheel. Install the needle bearing, having tracked hit of a pin of a case in a reception opening.
5. Apply sealant like Three Bond 1215 on the interfaced surface and press to each other transmission semi-cases, - track that between semi-cases adjusting washers of the leading gear wheel of a reverse gear and the holder of an entrance shaft were not clamped. Make sure that the speedometer gear wheel correctly entered gearing.
6. Working strictly in a certain order, tighten with the demanded effort of 17 coupling bolts.

 Bolts are entered from below, nuts well up from above.

6. Tighten bolts of fastening of the ball bearing of a shaft of the leading gear wheel with the demanded effort (29 Nanometers).

7. Adjust a side play of gearing of a gipoidny wheel and a pretightness of the roller bearing, - use the special lock ST 498427100 adaptation.

8. Put transmission by the left side down and establish ST1 399780104 freight on a cup of the bearing and by means of a key of ST2 499787000 screw below in the left semi-case of transmission the holder. Connect the ST3 499927100 handle to a pin of primary shaft, include the 4th or 5th transfer and several times turn a shaft. Turning a shaft the handle, roll the holder until weakness in resistance emergence to turning of a key of ST2 testifying to an entrance of a gipoidny wheel to gearing with the leading gear wheel of the main transfer. For a guarantee of providing a normal spot of contact of gear wheels repeat the described procedure several times.

9. Remove freight of ST1 and, without establishing a sealing ring, screw the holder in the right semi-case of transmission, - continue to roll the holder until emergence of resistance.

10. Establish a lock plate and for the purpose of providing the demanded gearing side play, on 1.5 teeth of a plate release the lower holder, on a touch size having tightened the top.

The turning of a plate leads to shift of teeths at 1/2 lengths of tooth.

12. Temporarily tighten both lock plates and mark position of holders concerning plates.
13. Turning primary shaft, slightly tap the holder a hammer with soft the brisk.
14. Check and adjust a side play of gearing and a spot of contact of teeths of a gipoidny gear wheel (see the Section Removal, service, installation and adjustment of forward differential), then remove a lock plate.

41 Having released the holder, put a sealing ring in the opened reception flute, then return the holder to former situation and tighten a lock plate with the demanded effort. Repeat the described procedure for the second holder.

42 Pick up a back plate of primary shaft (see the Section Removal, service, installation and adjustment of primary shaft of RKPP).
43 Further installation is made as it should be, the return to an order of dismantle of components.


Models with an additional two-level reducer

 PERFORMANCE ORDER

Installation is made as it should be, the return to an order of dismantle of components taking into account the features described in the subsection devoted to installation of a case of transmission assembly on models without two-level reducer.