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 and installation of assembly of a shaft of the leading gear wheel of the main transfer of the drive of forward wheels

Design of assembly of the leading gear wheel of forward differential

1 — the Shaft of the leading gear wheel
2 — the Roller bearing
3 — the Washer
4 — the Persistent bearing
5 — the Needle bearing
6 — the Conducted shaft
7 — the Spline
8 — the Segment spline
9 — the Ring of the leading gear wheel
10 — the Needle bearing
11 — the External spring lock ring
12 — the Washer
13 — the Gear ring
14 — the Conducted gear wheel of the 1st transfer
15 — the Blocking synchronizer ring
16 — the Nave of the synchronizer 1/2 of transfers
17 — the Sliding key
18 — the Conducted gear wheel of a reverse gear
19 — the Blocking synchronizer ring with external gearing
20 — a synchronizer Cone
21 — the Blocking synchronizer ring with internal gearing

22 — the Conducted gear wheel of the 2nd transfer
23 — the Plug of the conducted gear wheel of the 2nd transfer
24 — the Conducted gear wheel of 3/4 transfers
25 — Adjusting laying of the conducted gear wheel
26 — the Roller bearing
27 — the Conducted gear wheel of the 5th transfer
28 — the Lock washer
29 — the Lock-nut
30 — the Washer
31 — the Persistent bearing
32 — the Plug of a conic gear wheel of differential
33 — the Washer
34 — the Lock washer
35 — the Lock-nut

Efforts of a tightening of threaded connections, Nanometer

T1: 29
T2: 118
T3: 265


Removal of the leading gear wheel

A — the Plug of a conic gear wheel of differential
B — the Washer No. 1 (25kh37.5kh t)
With — the Persistent bearing (25х37.5х3)
D — the Washer No. 1 (25x37.5x4)

E — the Needle bearing (25х37.5х20)
F — the Ring of the leading gear wheel
G — the Needle bearing (30х37х23)
H — the Persistent bearing (33х50х3)


Removal of the conducted gear wheel of the 2nd transfer, the blocking rings and a cone of the synchronizer

A — the Conducted gear wheel of the 2nd transfer
B — the Blocking ring of internal gearing

With — a synchronizer Cone
D — the Blocking ring of external gearing

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 (see the Section Removal, installation and check of a condition of a case of transmission assembly).
4. Take assembly of a shaft of the leading gear wheel, - in case of need hook assembly by the hammer handle.

DISMANTLING

 PERFORMANCE ORDER

 In order to avoid damage of the conducted shaft in the course of dismantling or a partition wind with rags the end of a shaft turned to the frictional party of the persistent needle bearing the end!


1. A lock-nut also give to Raschekanta it by means of the holder of ST1 899884100, an emphasis of ST2 498427100 and a face key of ST3 899988608.

2. Remove the leading gear wheel from the leading shaft. For this purpose remove the plug of a conic gear wheel of differential, adjusting washers No. 1 and No. 2, the persistent bearing, the needle bearing, a ring of the leading gear wheel, the needle bearing and the persistent bearing.
3. By means of a press and a stripper of ST 498007000 remove the roller bearing and a washer.

4. The second lock-nut also give to Raschekanta it by means of the holder of ST2 899884100 and a face key (50) ST3 499987300.

5. By means of a stripper of ST 499857000 remove the conducted gear wheel of the 5th transfer.

6. Take a segment spline.

7. By means of a mandrel of ST1 499757002 and a stripper of ST2 899714110 remove the roller bearing and the conducted gear wheel of 3/4 transfers.

8. Take a direct spline.
9. Remove the conducted gear wheel of the 2nd transfer, the blocking ring of internal gearing, a cone of the synchronizer and the blocking ring of external gearing.
10. By means of a mandrel of ST1 499757002 and a stripper of ST2 899714110 remove the conducted gear wheel of the 1st transfer, the plug of a gear wheel of the 2nd transfer and assembly of a gear wheel with a nave.

 Assembly of a gear wheel with a nave has to be in case of need replaced. The gear wheel 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.

11. Remove a gear ring of the conducted gear wheel of the 1st transfer.

CHECK

 PERFORMANCE ORDER

1. Check is similar to the corresponding operations described in the Section Removal, service, installation and adjustment of primary shaft of RKPP.

 Check of smoothness of rotation of the ball bearing installed from the back party of assembly of a shaft of the leading gear wheel has to be made before removal of components of a shaft, otherwise the bearing pretightness will be eliminated!


And — Assembly of a shaft of the leading gear wheel of the main transfer
In — the Ball bearing

2. Besides, check the size of a gap (A) between trailer surfaces of the blocking ring which is wrung out to a cone and gear wheels. If the result of measurement makes less than 0.5 ÷ 1.0 mm, replace a ring.

ASSEMBLY

Installation of the coupling and assembly of a gear wheel with the plug

A — To a gear wheel of the 1st transfer
B — To a gear wheel of the 2nd transfer

With — the surfaces Brought to one level
D — Steps


 PERFORMANCE ORDER

1. Watching combination of landing tags, install the coupling and assembly of a gear wheel with a nave.
2. Establish a washer and a spring lock ring, then establish a gear ring of the conducted gear wheel of the 1st transfer.
3. Put on the conducted shaft the conducted gear wheel of the 1st transfer, the blocking ring of the synchronizer of the 1st transfer and assembly of a gear wheel with a nave, - track that assembly of a gear wheel with a nave was developed correctly, and the sliding key got to a groove of the blocking ring.

4. By means of a press and mandrels of ST1 499277200 and ST2 499587000 put the plug of the conducted gear wheel of the 2nd transfer on the conducted shaft, - wind the end of a shaft with rags (see the prevention at the beginning of the subsection "Dismantling"). At installation of a press track correctness of combination of oil openings of a shaft and the plug.

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

5. Put the conducted gear wheel of the 2nd transfer, the external blocking ring, a synchronizer cone blocking a ring of external gearing and the sliding key on the conducted shaft.
6. Further assembly is made as it should be, the return to an order of dismantle of components. The effort of a tightening of the second lock-nut makes 265 Nanometers.

7. After a lock-nut zachekanivaniye in two points by means of a steelyard check the initial moment of a provorachivaniye of the roller bearing, - the result of measurement should not exceed the limit of the range of 0.1 ÷ 1.5 N.

8. Track correctness of installation of the roller bearing, the opening under a pin in its external holder is located asymmetrically.

And — the Bearing
In — the Opening under a pin

Adjustment of a pretightness of the persistent bearing

 PERFORMANCE ORDER

1. Make selection of an adjusting washer No. 1 so that the gap of "H" approximately seemed zero. Establish usual (18.3х30х4) and lock (18х30х2) washers, then screw the first lock-nut (18х13.5) and tighten it with effort of 118 Nanometers.

2. Remove an emphasis of ST2 498427100 and measure initial effort of a provorachivaniye of the bearing.
3. If the result of measurement exceeds the limit of admissible range (54 ± 25 Nanometers), address to the table given below and pick up a new adjusting washer No. 1, then repeat check.

Selection of an adjusting washer No. 1

detail No. Thickness, mm
803025051 3.925
803025052 3.950
803025053 3.975
803025054 4.000
803025055 4.025
803025056  4.050
803025057 4.075

4. If it is not possible to achieve satisfactory result by selection of a washer No. 1, address to the table given below and make an exaction of an adjusting washer No. 2 and repeat the operations described in paragraphs with 1 on 3.

 For increase in initial effort of a provorachivaniye and size of a gap of "H" it is necessary to use thicker adjusting washer No. 2, otherwise - thinner.


And — the Washer No. 1
In — the Washer No. 2

Selection of an adjusting washer No. 2

part No. Thickness, mm
803025059 3.850
803025054 4.000
 803025058 4.150

5. Double-check initial effort of a provorachivaniye of the bearing, then fuller a lock-nut in four points.

INSTALLATION

 PERFORMANCE ORDER

1. Remove assembly of forward differential.

2. Achieve combination of numerical tags of the leading main transfer to transfer conducted gear wheels. The top number on the leading gear wheel serves for its combination with a tag of the conducted gear wheel, lower - for selection of adjusting laying. Absence of number corresponds to its zero value.

3. Establish assembly of the leading gear wheel of the main transfer without adjusting washer to the right section of the main case of transmission and tighten bolts of fastening of the bearing.

4. Prepare the measuring instrument of the leading gear wheel (ST 499917500) for work: weaken two bolts and adjust the measuring instrument so that at removal of an end face of a plate in the end of a scale the measuring instrument registered value 0.5.

A — the Plate
B — the Scale

5. Install the measuring instrument, having inserted its pin into a reception opening in the transmission case.

6. Shifting a measuring instrument scale a finger, consider the indication in a point when where it is combined with a face surface of the leading gear wheel.

A — Remove a gap in zero in the absence of adjusting laying

7. The demanded thickness of adjusting laying is defined by addition to indications of the measuring instrument of value of the numerical marking which is put down on the leading gear wheel in case before a numerical tag on the leading gear wheel the sign "+" is put down, or in the way to the same number if before it the sign "-" is put down.
8. Try to achieve the maximum approach to the demanded value by selection of a combination from 1 to 3 adjusting laying. The list of the let-out laying is given in the table given below.

Thickness of the let-out adjusting laying of the leading gear wheel

detail No. Thickness, mm
32295AA031 0.150
32295AA041 0.175
32295AA051 0.200
32295AA061 0.225
32295AA071 0.250
 32295AA081 0.275
32295AA091 0.300
32295AA101 0.500

9. Establish assembly of differential.
10. Establish assemblies of primary shaft and a shaft of the leading gear wheel, - track that at shift of both assemblies against the stop forward the gap between them completely got out. Check serviceability of functioning of forks of gear shifting (1/2, 3/4 and 5), - the coupling and the conducted gear wheel of a reverse gear have to settle down on the center of assemblies of the synchronizers.
11. Further installation is made as it should be, the return to an order of dismantle of components.