Subaru Legacy/Outback

1. Remove assembly of RKPP (see the Section Removal and installation of transmission assembly).
2. Remove a transfer case with the lengthening case (see the Section Removal, service and installation of a transfer case and lengthening of transmission).
3. Remove a transmission case.
4. Remove assembly of a shaft of the leading gear wheel of the main transfer (see the Section Removal, service and installation of assembly of a shaft of the leading gear wheel of the main transfer of the drive of forward wheels).
5. Remove assembly of primary shaft.

1. For the purpose of prevention of damage of an epiploon wind with an insulating tape of a vent of primary shaft, then manually take an epiploon and the needle bearing.

2. Raschekante also turn off a lock-nut from assembly of primary shaft. ST1 498937000 Holder ST2 499987003 Face key (35)

3. Remove from primary shaft the coupling of the synchronizer 5-y/zadney of transfers with a nave, the blocking ring of the synchronizer and the leading gear wheel of the 5th transfer with the needle bearing.

4. Remove from assembly of the coupling with a nave a spring lock ring and a stopper of a cone of the synchronizer.

And — the Ball bearing In — the Cone With — the Blocking ring 5. By means of special adaptations (ST1 499757002 and ST2 498077400) and the press remove the ball bearing, a cone and the blocking ring of the synchronizer of a reverse gear.  Assembly of the coupling with a nave is subject to replacement without fail. The coupling is in continuous gearing with a nave and in case of need dismantle of assembly it is necessary to mark previously the original provision of components from each other. The ball bearing is also not subject to a reuse and has to be replaced.

6. By means of special strippers of ST1 899864100 and ST2 899714110 remove the remained components from primary shaft.

1. Carefully wash out all removed components.
2. Manually check smoothness and noiselessness of rotation of bearings. Estimate degree of wear of bearings, check balls and rings for existence of mechanical damages and signs of development of corrosion. Replace defective components.
3. Plugs are subject to replacement, in case of identification of damages of a surface of sliding, signs of excessive wear, threadbare sites of internal walls, etc. of defects.
4. Replace gear wheels with broken, excessively worn-out or otherwise the damaged teeths.
5. Gear wheels are subject to replacement or restoration if the cone contacting to the blocking ring of the synchronizer has roughnesses or is damaged, and also in case of damage of internal or face surfaces.
6. The blocking rings should be checked for existence of damages and signs of wear of internal or face surfaces. Make sure also of lack of excessive wear and zadir of contact surfaces of grooves under the sliding keys.
7. The sliding keys are replaced in case of identification of signs of the slightest wear or damage.
8. Estimate a condition of working edges of an epiploon. In case of identification of deformations, signs of hardening of rubber or mechanical damages the epiploon is subject to replacement.
9. The sealing ring will be reasonable to be replaced regardless of its current state.
10. Estimate also a condition of components of the mechanism of switching of transfer. In case of need make the corresponding recovery repair, replace worn out, deformed or otherwise the damaged components.

2. Put on primary shaft the leading gear wheel of the 3rd transfer, the blocking ring and assembly of the coupling of the synchronizer of the 3rd transfer with a nave, - track hit of the sliding key in a groove of the blocking ring.

3. By means of special ST1 899714110 and ST2 499877000 adaptations and a press put a holder of the needle bearing of a gear wheel of the 4th transfer on primary shaft.  The enclosed landing effort should not exceed 10 kN (1 ton)! A bearing Holder

4. Put on a shaft the blocking ring, the needle bearing and the leading gear wheel of the 4th transfer with the persistent washer, - track correctness of combination of the blocking ring and assembly of a gear wheel with a nave with key flutes. A — Flutes B — To a gear wheel of the 4th transfer

5. By means of special ST1 899714110 and ST2 499877000 adaptations and a press put the ball bearing on a back pin of primary shaft.

The enclosed landing effort should not exceed 10 kN (1 ton)!

6. By means of the same adaptations establish a persistent washer and a holder of the needle bearing of a gear wheel of the 5th transfer, - develop a persistent washer the party equipped with flutes to a gear wheel of the 5th transfer.

The enclosed landing effort should not exceed 10 kN (1 ton)!

7. Install the bearing on a synchronizer cone.
8. By means of a mandrel of ST1 499757002 establish on assembly of the coupling of the synchronizer 5-y/zadney of transfers with a nave the blocking ring and a cone, - do not forget to replace the ball bearing.

Attention: The enclosed landing effort should not exceed 10 kN (1 ton)! Having finished installation, check freedom of rotation of a cone.

9. Establish on assembly of the coupling of the synchronizer 5-y/zadney of transfers with a nave a stopper of a cone and a spring lock ring.
10. Put the remained components on a back pin of primary shaft, - track hit of the sliding key in a groove of the blocking ring.
11. By means of a face key of ST1 499987003 and the holder of ST2 498937000 tighten with the demanded effort (118 Nanometers) of a lock-nut.

1. Make assembly of couplings of all synchronizers with the naves. Track that springs were developed by locks at an angle 120 ° from each other.
2. Put on primary shaft the leading gear wheel of the 3rd transfer, the blocking rings of external and internal gearing and assembly of the coupling of the synchronizer of the 3rd transfer with a nave, - track hit of the sliding key in a groove of the blocking ring.
3. Further assembly is made the order similar described above for models of 2.0 l.

2. Further installation is made as it should be, the return to an order of dismantle of components.

Selection of a back plate of primary shaft

Size (A), mm	detail No.	Marking
4.00 ÷ 4.13	32294AA041	1
3.87 ÷ 3.99	32294AA051	2

Procedure of removal is similar, described above for models without two-level reducer, with only that difference that primary shaft is taken together with entrance.

1. Dismantling is made in the manner similar described above for models without two-level reducer.

2. Before demontazhy components of the last turn, by means of special nippers of ST 899474100 remove a spring lock ring from primary shaft.

1. Carefully wash out all removed components.
2. Manually check smoothness and noiselessness of rotation of bearings. Estimate degree of wear of bearings, check balls and rings for existence of mechanical damages and signs of development of corrosion. Replace defective components.
3. Plugs are subject to replacement, in case of identification of damages of a surface of sliding, signs of excessive wear, threadbare sites of internal walls, etc. of defects.
4. Replace gear wheels with broken, excessively worn-out or otherwise the damaged teeths.
5. Gear wheels are subject to replacement or restoration if the cone contacting to the blocking ring of the synchronizer has roughnesses or is damaged, and also in case of damage of internal or face surfaces.
6. The blocking rings should be checked for existence of damages and signs of wear of internal or face surfaces. Make sure also of lack of excessive wear and zadir of contact surfaces of grooves under the sliding keys.
7. The sliding keys are replaced in case of identification of signs of the slightest wear or damage.
8. Estimate a condition of working edges of an epiploon. In case of identification of deformations, signs of hardening of rubber or mechanical damages the epiploon is subject to replacement.
9. The sealing ring will be reasonable to be replaced regardless of its current state.
10. Estimate also a condition of components of the mechanism of switching of transfer. In case of need make the corresponding recovery repair, replace worn out, deformed or otherwise the damaged components.

1. Put the needle bearing on primary shaft.
2. Put the components listed on an illustration on forward part of primary shaft. Track that the end face equipped with flutes was developed towards an entrance gear wheel, and the sliding key of the Hi/Lo synchronizer got to a reception groove of the blocking ring.
3. By means of special ST1 499757002 and ST2 499757001 adaptations establish the NEW spring lock ring on shtokovy section of primary shaft.

Selection of a ring is carried out according to the table of reasons of restriction of an axial gap given below between it and a nave of synchronizers limits of range of 0.06 ÷ 0.10 mm.

Selection of a spring lock ring

Assembly is made similar to the assembly described for models without two-level reducer taking into account the additions stated in the previous subsection.

Installation is made as it should be, the return to an order of dismantle of components. After installation of the needle bearing on a forward pin of a shaft dock the last with an output in bulk of transmission.

Selection of a back plate of primary shaft

Size (A), mm	detail No.	Marking
4.00 ÷ 4.13	32294AA041	1
3.87 ÷ 3.99	32294AA051	2