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 (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.

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.

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

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

Selection of an adjusting washer No. 2

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

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

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.