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, service, installation and adjustment of primary shaft of RKPP

Design of primary shaft of RKPP

1 — the Epiploon
2 — the Needle bearing
3 — Primary shaft of transmission
4 — the Needle bearing
5 — the Leading gear wheel of the 3rd transfer
6 — the Blocking ring with internal gearing (except models of 2.0 l)
7 — the Cone of the synchronizer of the 3rd transfer (except models of 2.0 l)
8 — the Blocking ring external gearing (except models of 2.0 l)
9 — the Coupling of the synchronizer 3/4 of transfers
10 — the Nave of the synchronizer 3/4 of transfers
11 — the Sliding key of switching 3/4
12 — the Blocking ring of the synchronizer of the 4th transfer
13 — the Leading gear wheel of the 4th transfer
14 — the Holder of the needle bearing of a gear wheel of the 4th transfer
15 — the Needle bearing
16 — the Persistent washer of a gear wheel of the 4th transfer
17 — the Ball bearing
18 — the Blocking synchronizer ring (model of 2.0 l)
19 — the Persistent washer of a gear wheel of the 5th transfer
20 — the Holder of the needle bearing of a gear wheel of the 5th transfer
21 — the Needle bearing
22 — the Back plate of primary shaft
23 — the Leading gear wheel of the 5th transfer

24 — the Blocking ring of the synchronizer of the 5th transfer
25 — the Sliding key of switchings 5-y/back transfers
26 — the Plug of the synchronizer 5-y/zadney of transfers
27 — the Coupling of the synchronizer 5-y/zadney of transfers
28 — the Blocking ring of the synchronizer of a reverse gear
29 — the Cone of the synchronizer of a reverse gear
30 — the Ball bearing
31 — a synchronizer cone Stopper
32 — the Spring lock ring
33 — the Lock washer
34 — the Lock-nut
35 — the Shaft of an intermediate gear wheel of a reverse gear
36 — the Pin
37 — the Intermediate gear wheel of a reverse gear
38 — the Washer

Efforts of a tightening of a threaded connection, Nanometer

Т: 118


Models without additional two-level reducer

REMOVAL

 PERFORMANCE ORDER

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.

DISMANTLING

 PERFORMANCE ORDER

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.

CHECK

 PERFORMANCE ORDER

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.

ASSEMBLY

Models of 2.0 l

Installation of the remained components

A — the Needle bearing
B — the Leading gear wheel of the 5th transfer
With — the Blocking ring

D — Assembly of the coupling of the synchronizer 5-y/zadney of transfers with a nave
E — the Lock washer
F — the Lock-nut


Installation of components of the drive of the 3rd transfer

A — the Needle bearing
B — the Leading gear wheel
With — the Blocking ring of internal gearing

D — a synchronizer Cone
E — the Blocking ring of external gearing
F — Assembly of the coupling of the synchronizer with a nave


 PERFORMANCE ORDER

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 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.

Models of 2.5 l

 PERFORMANCE ORDER

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.

INSTALLATION

 PERFORMANCE ORDER

1. Put the needle bearing and the NEW epiploon on a forward pin of primary shaft, - for the purpose of prevention of damage of an epiploon wind shlitsevy part of a shaft with an insulating tape. Before installation grease sealing sponges of an epiploon with greasing like Unilube #2, track that the face surface of an epiploon was combined with a landing surface (And), and the directing pin of a case of transmission got to a reception opening in an external holder of the needle bearing.

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

ADJUSTMENT

 PERFORMANCE ORDER

By means of the measuring instrument of depth of ST 498147000 measure the size of a vystupaniye (A) of the ball bearing over a transmission case surface. Proceeding from results of the taken measurement make selection suitable on a back plate of primary shaft according to the table given below.

 Before measurement slightly knock with a hammer with soft brisk on an end face of primary shaft for the purpose of a gap vybiraniye between a surface of the main case and a mobile flange of the bearing.

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


Models with an additional two-level reducer

REMOVAL

 PERFORMANCE ORDER

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.

DISMANTLING

 PERFORMANCE ORDER

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.

CHECK

 PERFORMANCE ORDER

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.

ASSEMBLY

Models of 2.0 l

The components of primary shaft removed in the last turn

A — Assembly of the coupling of the synchronizer with a nave
B — the Blocking Hi/Lo synchronizer ring
With — the Frictional damper
D — the Entrance gear wheel of the lowering mode

E — the Needle bearing
F — the Remote pro-rate of an entrance gear wheel of the lowering mode
G — the Ball


 PERFORMANCE ORDER

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

detail No. Thickness, mm
805025051 2.42
805025052 2.47
805025053 2.52
805025054 2.57
 805025055 2.62
805025056 2.67
805025057 2.72
805025058 2.87

Models of 2.0 l

 PERFORMANCE ORDER

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

 PERFORMANCE ORDER

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.

ADJUSTMENT

 PERFORMANCE ORDER

By means of the measuring instrument of depth of ST 498147000 measure the size of a vystupaniye (A) of the ball bearing over a transmission case surface. Proceeding from results of the taken measurement make selection suitable on a back plate of primary shaft according to the table given below.

 Before measurement slightly knock with a hammer with soft brisk on an end face of primary shaft for the purpose of a gap vybiraniye between a surface of the main case and a mobile flange of the bearing.

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