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




d9f1bda0



Removal, check of a state and installation of forks and rods of gear shifting

Gear shifting mechanism design

1 — the gear shifting mechanism Lever
2 — the Rod of a fork of inclusion of the 5th transfer
3 — the Pin
4 — the Rod of a fork of inclusion of a reverse gear
5 — Traffic jams of control balls
6 — Sealing washers
7 — Springs of control balls
8 — Control balls
9 — the Rod of a fork of switching of 3/4 transfers
10 — the Blocking plungers
11 — the Rod of a fork of switching of 1/2 transfers
12 — the Fork of switching of 3/4 transfers
13 — the Fork of switching of 1/2 transfers

14 — the Ball
15 — the Spring
16 — the External spring lock ring
17 — the Lever of a rod of a fork of inclusion of a reverse gear
18 — the Lever of inclusion of a reverse gear

Efforts of a tightening of threaded connections, Nanometer

Т: 19.6

REMOVAL

 PERFORMANCE ORDER

1. Remove assembly of RKPP (see the Section Removal and installation of transmission assembly).
2. Remove sensors switches of fires of a backing and neutral situation RKPP (see the Section Removal, installation and check of a condition of sensors switches).
3. Remove a transfer case with the lengthening case (see the Section Removal, service and installation of a transfer case and lengthening of transmission).
4. Remove a transmission case (see the Section Removal, installation and check of a condition of a case of transmission assembly).
5. Remove assembly 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).
6. Remove assembly of primary shaft (see the Section Removal, service, installation and adjustment of primary shaft of RKPP).
7. Remove assembly of forward differential (see the Section Removal, service, installation and adjustment of forward differential).

8. By means of a drift of ST 398791700 take a pin and remove a fork of inclusion of the 5th transfer.

A — the Pin
B — the Fork of inclusion of the 5th transfer

9. Turn out traffic jams, then take springs and control balls of clamps.

10. Take a pin and remove a fork of switching of 3/4 transfers with the rod.

Beat out a pin inside that it did not rest against a case wall. At extraction of a rod other rods have to be in neutral situation.


A — the Pin
B — the Rod of a fork of switching of 3/4 transfers
With — the Fork

11. Take a pin and remove a fork of switching of 1/2 transfers with the rod.
12. Remove an external spring lock ring and pull down the lever from a rod of a fork of inclusion of a reverse gear, - try not to lose a ball. Further remove a ball with a spring and take the blocking plunger from a rod. Remove a rod.
13. Remove the lever of inclusion of a reverse gear.

CHECK

 PERFORMANCE ORDER

1. Check shaft and rods of gear shifting for existence of signs of excessive wear, deformations and other mechanical damages. Replace defective components.

2. Measure sizes of gaps between the conducted gear wheels of the 1st, 2nd and back transfers. If results of measurements do not correspond requirements of Specifications (9.5 mm), address to the table given below and make selection of a new fork of switching of 1/2 transfers.

A — the Conducted gear wheel of the 1st transfer
B — the Conducted gear wheel of a reverse gear
With — the Conducted gear wheel of the 2nd transfer

The list of the let-out forks of switching of 1/2 transfers


3. Measure sizes of gaps between the leading gear wheels of the 3rd and 4th transfers and the coupling of the synchronizer. If results of measurements it do not meet requirements of Specifications (9.3 mm), address to the table given below and make selection of a new fork of switching of 3/4 transfers.

A — the Leading gear wheel of the 3rd transfer
B — the synchronizer Coupling
With — the Leading gear wheel of the 4th transfer

The list of the let-out forks of switching of 3/4 transfers


4. Measure gap size between the leading gear wheel of the 5th transfer and the coupling of the synchronizer. If the result of measurement does not conform to requirements of Specifications (9.3 mm), address to the table given below and make selection of a new fork of inclusion of the 5th transfer.

A — the Leading gear wheel of the 5th transfer
B — the synchronizer Coupling

The list of the let-out forks of inclusion of the 5th transfer


5. Measure sizes of gaps between tips of rods. If results of measurements exceed the limit of admissible ranges, replace the corresponding components.

Gap And (1/2 - 3/4): 0.4 ÷ 1.4 mm
Gap In (3/4 - 5): 0.5 ÷ 1.3

INSTALLATION

 PERFORMANCE ORDER

1. Install on the lever of a rod of a fork of inclusion of a reverse gear a spring, a ball and the blocking plunger in the lever, - for temporary fixing of a plunger apply on it dab of jellied greasing. Insert a rod of a fork of inclusion of a reverse gear in an opening in its lever and record assembly by an external lock ring.
2. Put in an opening of a rod of inclusion of a reverse gear in the left part of a case of transmission a ball with a spring, establish a new sealing washer, then screw and tighten a stopper.

 Landing of a ball is made by means of the special ST 399411700 adaptation.

3. Through an opening on back part of a case of transmission pass a rod of a fork of switching of 1/2 transfers to the corresponding fork.
4. Achieve combination of openings on a fork and a rod and insert into them a new pin.

 Other rods should be transferred to neutral situation. Make sure that the blocking plunger is on the party of a rod of a fork of switching of 3/4 transfers. For temporary fixing of a plunger apply on it dab of jellied greasing.

5. Establish the blocking plunger in a rod of a fork of switching of 3/4 transfers.
6. Through an opening on back part of the case of transmission pass a rod of switching of 3/4 transfers to the fork.
7. Achieve combination of openings on a fork and a rod and insert into them a new pin.

 The rod of a reverse gear should be transferred to neutral situation. Make sure that the blocking plunger is on the party of a rod of a fork of inclusion of a reverse gear.

8. Put a fork of inclusion of the 5th transfer on the back end of the rod, achieve combination of openings and pass throughout them the NEW pin.
9. Fill balls, their springs and new sealing washers in openings of rods of switching of 1/2 and 3/4 transfers, screw and tighten traffic jams.
10. Further installation is made as it should be, the return to an order of dismantle of components.