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 forward differential

Design of forward differential of RKPP

1 — the Shaft of the leading gear wheel of the main transfer
2 — the Conducted gear wheel of the main transfer
3 — the Axis of satellites
4 — the Pin
5 — the Washer
6 — Lateral gear wheels of differential
7 — Satellites
8 — the External spring ring
9 — the Roller bearing
10 — a differential Box

11 — Epiploons
12 — Lateral holders
13 — Sealing rings
14 — Elements of a torque transmission to power shafts
15 — Lock plates of holders

Efforts of a tightening of threaded connections, Nanometer

T1: 25
T2: 62

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. Remove assembly of a shaft of the leading gear wheel (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 (see the Section Removal, service, installation and adjustment of primary shaft of RKPP).
6. Remove assembly of forward differential.

 Try not to mix external holders of the left and right roller bearings and not to damage epiploons of holders!

DISMANTLING

Differential box

 PERFORMANCE ORDER

1. Remove spring lock rings and take elements of a torque transmission to the left and right power shafts.

 At assembly both elements have to be established strictly on the former places!

2. Release fixing 12 bolts and remove the gipoidny conducted gear wheel of the main transfer.

3. By means of a drift of ST 899904100 beat out a pin from assembly of differential, - the pin is beaten out towards the conducted gear wheel.

4. Take an axis of satellites and internal components of differential (satellites, lateral gear wheels and washers).

5. By means of a stripper of ST 399527700 dismantle the ball bearing.


Lateral holders

 PERFORMANCE ORDER

1. Remove sealing rings and epiploons.

 At assembly epiploons are subject to replacement without fail!


2. Prepare ST 398527700 stripper for work: to a rasshplintuyta also take forelocks, then remove captures.

A — Captures of a stripper
B — Forelocks
With — Pins

3. Reliably fix two captures on an external holder of the bearing and establish ST 398527700 stripper. Strongly record two spindles on the lateral holder, then by means of pins fix captures to a stripper (do not forget to insert forelocks).

A — Spindles
B — Capture of a stripper

4. Having tracked that spindles of a stripper did not drop out of the holder, release from the last an external holder of the bearing.

 The external holder of the bearing is replaced complete with the internal.


A — Spindles
B — the Holder

5. Working in a similar manner, remove the bearing from the second holder.
6. Examine surfaces of sliding of a box of differential, check a condition of all gear wheels of differential and the roller bearing on a shaft of the leading gear wheel of the main transfer. Replace defective components.

ASSEMBLY

Differential box

 PERFORMANCE ORDER

1. Establish on the places in a differential box internal components and fill into place an axis of satellites.

 Washers have to be established by the parties with chamfered to satellites.


2. By means of the dial measuring instrument of the plunger ST2 49824700 type with the magnetic basis of ST1 49824700 measure side plays of gearing of satellites with lateral gear wheels of differential. If the result of measurement exceeds the limit of the range of 0.13 ÷ 0.18 mm, make the corresponding adjustment by selection for the table of washers of the corresponding thickness given below.

 

 At measurement track that teeths of gear wheels were in gearing.

Thickness of the let-out washers for adjustment of side plays of gearing of satellites with lateral gear wheels

detail No. Thickness, mm
8030308021 0.925 ÷ 0.950
8030308022
0.975 ÷ 1.000
8030308023  1.025 ÷ 1.050

3. Achieve combination of openings in an axis of satellites with openings in a box of differential and establish into place a pin, having filled it from installation of the conducted gear wheel.

4. By means of a mandrel of ST1 499277100 and a nozzle of ST1 499277101 put the roller bearing in the differential case.

 The enclosed landing effort should not exceed the 10th arm (1 ton)! 12 bolts fix the conducted gear wheel, - the effort of a tightening of bolts makes 62 Nanometers.


Lateral holders

 PERFORMANCE ORDER

Assembly is made as it should be, the return to an order of dismantle of components. Epiploons are established by means of ST1 49979700 mandrel. Track that NEW sealing rings were not excessively extended or overwound.

INSTALLATION

 PERFORMANCE ORDER

1. By means of the ST 499787000 adaptation put in differential lateral holders.
2. Further installation is made as it should be, the return to an order of dismantle of components.

 Try not to allow wraparounds of sponges of epiploons at installation of differential. In order to avoid damage of epiploons wind vents of elements of the drive of power shafts with an insulating tape!


Check and adjustment of a side play of gearing of gear wheels of the main transfer

CHECK

By means of the dial measuring instrument

 PERFORMANCE ORDER

1. By means of a plate of ST3 498255400 fix the magnetic basis of ST1 49824700 of the dial measuring instrument of the plunger ST2 498247001 type on RKPP case, pass a measuring instrument plunger throughout a drain opening of a case, having rested it it is perpendicular in a surface of tooth of a gipoidny wheel. The admissible size of a side play lies within the range of 0.13 ÷ 0.18 mm.

By studying of contact spots of gearing of teeths

 PERFORMANCE ORDER

1. Cover both surfaces of three-four teeths of the conducted gear wheel of the main transfer with a uniform layer of lead minium. Turning primary shaft of transmission, rotate assembly back and forth until on minium contact spots do not accurately imprint.

A — Toes
B — the Persistent party
With — Heels
D — the Leading party

2. Options of a possible arrangement of spots of contact are given in illustrations. In case of need make the corresponding adjustment (see below).

ADJUSTMENT

 PERFORMANCE ORDER

 See also Section Removal, installation and check of a condition of a case of transmission assembly.


1. Adjustment of a side play is made by rotation of the right holder by ST 499787000 key.

 Turn of the holder on one tooth, leads to change of a side play on 0.05 mm.

2. For reduction of a side play weaken the right holder and on the same quantity of turns tighten the left. Weakening of the left holder with pulling up of the right leads to increase in a side play.
3. Being guided by an arrangement of spots of contact of teeths of gear wheels, pick up the demanded adjusting washer of the leading gear wheel of the main transfer.