Subaru Legacy/Outback

1999-2003 of release

Repair and car operation



Subaru Legasi, Autbek
+ Cars Subaru Legacy, Outback
+ The operation manual
+ Routine maintenance
+ The engine
+ Systems of cooling, heating
+ The power supply system and release
+ Engine electric equipment
+ Manual box and differential
+ Automatic transmission
- Coupling
   Specifications
   + Flywheel and coupling
   - Приводные and карданный shaft, back differential
      Drive of forward wheels - the general information
      Removal and installation of rotary fists, service ступичных assemblages of forward wheels
      Removal, service and installation of a forward power shaft
      Drive of back wheels - the general information
      Removal and installation ступичных assemblages of back wheels, replacement back ступичного the bearing
      Removal, check of a condition and installation of components карданного a shaft
      Check of a condition and replacement of a forward epiploon of back differential
      Removal, service, installation and adjustment of back differential of T-type
      Removal, service, installation and adjustment of back differential of VA-type
      Removal, installation and check of a condition of a forward beam of fastening of back differential
      Removal, service and installation of a back power shaft
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment





Removal, service, installation and adjustment of back differential of T-type

REMOVAL

Design of back differential

A — Lateral gear wheels
B — Satellites
C — the Persistent washer

D — a differential Box
E — the Axis of satellites


 PERFORMANCE ORDER

1. Disconnect a negative cable from the battery.
2. Establish selector AT lever in position źN╗ / include neutral transfer (РКПП)
3. Give wheel nuts.
4. Release a lay brake.
5. Поддомкратьте the car also establish it on props.
6. Remove wheels.
7. Remove back section of system of release of the fulfilled gases with the muffler (see the Head of the Power supply system and release).
8. Uncover a thermofilter (see the Head of the Power supply system and release).
9. Remove карданный a shaft (see Has undressed Removal, check of a condition and installation of components карданного a shaft).
10. Prepare трансмиссионный a jack and fixing belts.

11. Release самоконтрящиеся nuts of fastening of back differential to a back beam.

12. By means of stripper ST 28099PA100 liberate the SHRUS of a back power shaft from back differential.

A the Bolt

13. Give nuts of protection of differential.

14. Remove a forward beam of back differential and prop up back differential трансмиссионным a jack.

15. Belts rigidly fix back differential on a jack.
16. Give самоконтрящиеся nuts of fastening of back differential to a cross-section beam.
17. Accurately having chosen an approaching corner and position трансмиссионного a jack and its support, turn out from the plug of a cross-section beam a carving hairpin of back differential.
18. Lower a support трансмиссионного a jack, - try not to hook a power shaft about a bolt of the cross-section lever.
19. If yet have not made it, liberate from differential back power shafts, - in case of need take advantage of stripper ST 28099PA100.
20. Lower трансмиссионный a jack.
21. Tie up back power shafts to cross-section levers of a back suspension bracket.

22. Remove protection and a fixing plate of back differential.

A — Protection
B — the Fixing plate

DISMANTLING

Removal of the directing bearing

A — the Bearing of a leading gear wheel
B — the Forward bearing

C — the Cup of the back bearing


Adjustment of a pretightness of forward and back bearings of differential

A — the Washer of adjustment of height of a gear wheel
B — the Prorate of adjustment of a pretightness
C — the Washer of adjustment of a pretightness

ST1 — The False shaft
ST2 — The False plug


 PERFORMANCE ORDER

1. For the purpose of definition by true of a cause of defect, before dismantling of back differential check up stains of contact and люфт gearings of teeths корончатой and the leader of gear wheels of differential, measure palpation size корончатой and resistance to rotation of the leader of gear wheels.
2. Clamp in a vice holder ST 398217700 and fix on it assemblage of back differential.
3. Merge from differential oil.

4. Uncover сапуна, - cover replacement should be made only in case of the valid necessity.

A — the Cover сапуна
B — the Back cover картера differential


5. Release fixing bolts and remove a back cover картера differential, - in case of need обстучите a cover a hammer with soft brisk.

6. Mark adjusting positions of holders of the right and left lateral bearings. Turn out fixing bolts, establish on the case of differential stripper ST 398457700 and with its help remove holders, - all adjusting washers should develop together with the corresponding holder.

7. Take from картера a differential box, - try not to damage gear wheel teeths.

8. Remove from holders of lateral bearings sealing rings and epiploons, - at assemblage all sealing elements are subject to replacement without fail.

9. In case of need replacements of lateral bearings, take advantage for removal of their cups by stripper ST 398527700.

10. By means of the same stripper remove cones of bearings.

 Do not assort bearings without the necessity, all removed components at assemblage should be established strictly on the former places.

11. Turn out fixing bolts and remove корончатую a conducted gear wheel of differential.

 The further dismantling is not supposed.


12. Расчеканьте and by means of stripper ST 899904100 take корончатой gear wheels a lock pin of an axis of satellites (model without LSD).
13. Take an axis and gear wheels of satellites, lateral gear wheels and persistent washers (models without LSD).

 Do not mix the left, right, forward and back gear wheels.

14. Keeping a connecting flange key ST 498427200, release a nut of a leading gear wheel, then by means of a stripper dismantle a connecting flange.
15. With the help выколотки ST 398467700 wring out the end of a shaft of a leading gear wheel and take it together with a cone of the back bearing, the prorate of adjustment of a pretightness and a washer.

16. Having fixed a cone of the back bearing by means of adaptation ST 398517700, remove it from a shaft of a leading gear wheel.

17. By means of stripper ST 398527700 take from a box of differential an epiploon.
18. With the help выколотки ST 398467700 remove directing bearing together with a cone of the forward bearing.

19. In need of replacement of bearings beat out from a box of differential of their cup, - take advantage brass выколоткой.

And — Two диагонально the located groove
In — Brass выколотка

20. Carefully wash out all removed components and examine them. Defective details replace.
21. Check up a condition of lateral gear wheels and satellites, - at detection of cracks or задиров, and also at excessive deterioration contact surfaces of persistent washers replace corresponding components. Insignificant defects of teeths can be eliminated with the help оселка.
22. Check up bearings on presence of signs of jamming, deterioration, corrosion, estimate level of a noise background published at rotation. Defective components replace.
23. Check up a condition of persistent washers of lateral gear wheels and satellites. The worn out and damaged components replace.
24. Replace all sealing elements.
25. Estimate a condition картера differential, in case of revealing of signs of excessive deterioration of nests under installation of bearings, cracks and other mechanical damages make replacement.
26. The differential box is subject to replacement at revealing of signs of excessive deterioration, cracks and other mechanical damages.
27. Check up a condition of surfaces of a connecting flange contacting to an epiploon, in case of revealing of defects the flange is subject to replacement.

Assemblage and adjustment

 PERFORMANCE ORDER

 All sealing elements (rings and epiploons at assemblage are subject to replacement without fail! Do not forget to grease at installation sealing sponges of epiploons.

1. Assemblage is made in an order, the return to an order of dismantle of components. During assemblage check a condition of all established components, make necessary adjustments. Try not to mix an order of installation of washers and adjusting plates.

 Persistent washers, adjusting plates and components of bearings before installation carefully wipe and grease трансмиссионным with oil. Try not to mix a holder of the right and left bearings.


2. Adjust a pretightness of forward and back bearings by selection of remote prorates established between them and washers.

 The thickness of a washer of adjustment of height of a leading gear wheel on the given adjustment of influence does not render. Adjustment should be moved at the removed epiploon.

a) By means of handle ST1 398477701 and opravki/vykolotki ST2 398477703 запрессуйте a holder of the back bearing in a differential box;
b) Fill in a differential box false shock shaft ST1 398507702 with put on on it a washer of adjustment of height of a leading gear wheel and a new cone of the back bearing.

 If the washer is not deformed, it can be used repeatedly;

c) Establish the remote prorate and a washer of adjustment of a pretightness of the bearing, a cone of the forward bearing, false plug ST2 398507703, a connecting flange, a washer and a nut of a leading gear wheel;
d) For усадки components turn a false shaft manually ST1 398507704, then start to tighten the NEW nut of a leading gear wheel, measuring thus size of a pretightness of bearings. Pick up such adjusting prorate and a washer that at tightened with demanded effort (181 Nanometers) to a nut the pretightness corresponded to requirements listed in the table resulted more low.

 Use a new counternut. Do not exceed the top border of a nominal range of a pretightness (19.6 ¸ 28.4 Н: for the new bearing and 8.34 ¸ 16.67 Н: for the bearing which was in the use). At a tightening of a nut of a leading gear wheel block a false shaft from проворачивания by means of stopper ST2 398507704.

The list of let out prorates and washers of adjustment of a pretightness of forward and back bearings of back differential of T-type
Washer № details  Thickness, mm
  383705200 2.59
  383715200 2.57
  383725200 2.55
  383735200 2.53
  383745200 2.51
  383755200 2.49
  383765200 2.47
  383775200 2.45
  383785200 2.43
  383795200 2.41
  383805200 2.39
  383815200 2.37
  383825200 2.35
  383835200 2.33
  383845200 2.31
The prorate № details  Thickness, mm
  383695201 56.2
  383695202 56.4
  383695203 56.6
  383695204 56.8
  383695205 57.0
  383695206 57.2

3. Adjust height of a leading gear wheel by selection of the washer established between its back wall and a cone of the back bearing.

a) Establish false shaft ST1 398507702, a measuring instrument картера differential ST2 398507701 and false plug ST3 398507703 and will make demanded effort of a pretightness (19.6 ¸ 28.4 Н: for the new bearing and 8.34 ¸ 16.67 Н: for the bearing which was in the use) to forward and back bearings.

 Simultaneously establish temporarily picked up adjusting washer, preliminary having measured and having written down its thickness;

b) by ShChupom лезвийного type measure backlash N between a measuring instrument and an end face of a false shaft, - track, that the backlash between a measuring instrument and a differential box has been completely chosen;
c) Using formula T = T0 + N - – (Hх0.01) – 0.20 (where Т0 = the Thickness of the time established washer, Т = the Demanded thickness of an adjusting washer, N = the measuring instrument Indication, Н = Numerical marks on a head of a leading gear wheel) and the data resulted more low, pick up an adjusting washer of a demanded thickness and establish it instead of temporarily established. For example, let: T0 = 2.20 + 1.20 = 3.40 mm, N = 0.23 mm, H = + 1, then: T = 3.40 + 0.23 – 0.01 – 0.20 = 3.42 also it is necessary to establish an adjusting washer № 383605200.

The list of let out washers of adjustment of height of a leading gear wheel of back differential of T-type

№ details Thickness, mm
383495200 3.09
383505200 3.12
383515200 3.15
383525200 3.18
383535200 3.21
383545200  3.24
383555200 3.27
383565200 3.30
383575200 3.33
383585200 3.36
383595200 3.39
383605200 3.42
383615200 3.45
383625200 3.48
383635200 3.51
383645200 3.54
383655200 3.57
383665200 3.60
383675200 3.63
383695200 3.66

4. With the help оправки ST 398177700 запрессуйте on the place a cone of the back bearing.
5. Fill a leading gear wheel, in картер differential, establish in advance подобранныепроставку and a washer of adjustment of a pretightness of forward and back bearings.

6. By means of false plug ST1 398507703, cargo ST2 399780104 and оправки ST3 899580100 запрессуйте in картер a cone of the forward bearing.

7. Establish the prorate, then by means of cargo ST1 399780104 and оправки ST2 899580100 запрессуйте directing bearing.
8. With the help оправки ST 498447120 plant in картер differential the NEW epiploon, having filled it on depth of 1 mm, - do not forget to grease before installation an epiploon sponge.
9. With the help оправки ST1 899874100 and cargo ST2 399780104 запрессуйте a connecting flange.
10. By means of key ST 498427200 tighten with demanded effort (181 Nanometers) NEW самоконтрящуюся a nut.
11. Establish in a differential box lateral gear wheels and satellites with persistent washers, fill an axis of satellites.

 Before installation both parties of washers and a pin lateral a gear wheel it is necessary to grease трансмиссионным with oil.


12. Measure size люфта gearings of lateral gear wheels and adjust it by selection of corresponding persistent washers.

The list let out persistent adjustment washers люфта gearings of lateral gear wheels (T-type differential)

№ details Thickness, mm
383445201 0.75 ¸ 0.80
383445202 0.80 ¸ 0.85
383445203 0.85 ¸ 0.90
383445204 0.90 ¸ 0.95
383445205 0.95 ¸ 1.00

13. Grease teeths and persistent surfaces of lateral gear wheels трансмиссионным with oil and check up freedom of their rotation.
14. Fill in a box of differential a pin of blocking of an axis of satellites and зачеканьте it from both parties.
15. Establish on a differential box корончатую a leading gear wheel.

 Before вворачиванием bolts grease their carving part with fixing hermetic of type Three Bond 1324. A tightening of fixing bolts with demanded effort (103 Nanometers) make in a diagonal order, periodically tapping on their heads.

16. With the help оправки ST 398487700 запрессуйте in a box of differential a cone of the lateral bearing.

 At cone replacement replace as well a bearing cup.

17. Plant in the holder a cup of the lateral bearing, - try not to scratch working surfaces of components.

 Bearing assemblage is replaced complete with a cone.

18. With the help оправки запрессуйте in the holder of the lateral bearing the NEW epiploon, preliminary slightly grease interfaced surfaces of components трансмиссионным with oil.
19. Establish on the holder of the lateral bearing the NEW sealing ring.
20. Люфт gearings of a conducted gear wheel and a pretightness of lateral bearings are defined by selection of adjusting washers of holders of lateral bearings.
21. Fill a differential box in картер, - operate in an order, the return to an extraction order.
22. Establish adjusting washers of holders of lateral bearings and sealing rings in holders, from which they have been removed (do not mix!).

 Replace треснутые or sealing rings, also replace the adjusting washers broken or damaged by corrosion similar on a thickness.

The list of let out adjusting washers of holders of lateral bearings (T-type differential)

№ details Thickness, mm
383475201 0.20
383475202 0.25
383475203 0.30
383475204 0.40
383475205  0.50

23. Achieve combination of the arrows put on картер of differential and on holders of lateral bearings, - try not to damage rollers external holders of lateral bearings.
24. Tighten bolts of holders of lateral bearings with demanded effort (10.3 Nanometers), preliminary having greased their carving part with fixing hermetic of type Three Bond 1105.

25. Measure size люфта gearings корончатого wheels with a leading gear wheel.

26. Measure resistance of a leading gear wheel to rotation and compare result of measurement with received at measurement of the same parametre at the removed box of differential, - the size of increase in result should not fall outside the limits a range 2.9 ¸ 10.8 Н. In case of need pick up new adjusting washers of holders of lateral bearings and repeat check.
27. Check up palpation size корончатой gear wheels on its back surface, estimate smoothness of rotation of differential.
28. Check up and adjust stains of contact of teeths корончатой gear wheels for what put an equal layer of lead minium on both parties of three-four teeths and start to rotate differential until the accurate trace of a stain of contact is formed. In case of need make corresponding updating by repeated adjustment of height of a leading gear wheel, selection of new washers of holders of lateral bearings and adjustment люфта gearings.

 Upon termination of adjustment remove minium traces.

29. At impossibility of adjustment or excessive deterioration replace корончатую a gear wheel. At revealing of signs of jamming, задиров or cracks, replace корончатую a gear wheel complete with the leader.
30. Check up люфт gearings lateral and корончатой gear wheels, size of axial palpation корончатой gear wheels and size of a full pretightness of bearings. In case of need make corresponding updatings.
31. Establish a back cover and tighten bolts of its fastening with demanded effort (29 Nanometers).


Treatment of results of check of stains of contact of teeths корончатой and the leader of gear wheels of differential

Direction of adjustment of a leading gear wheel

Adjustment direction корончатой gear wheels


Variants of the form and arrangement of stains of contact of teeths

Condition
Contact stain
Adjustment
Correct gearing
The contact stain at rotation without loading is slightly displaced to a sock, - in the presence of loading the stain is displaced to a heel
Superficial gearing
It is excessively great люфт gearings

Can lead to increase of level of a noise background and скалыванию the ends of teeths


Increase a thickness of a lining of adjustment of height of a leading gear wheel to approach it to an axis корончатой gear wheels
Lateral gearing
Люфт gearings it is insufficient

Can cause to lead to increase of level of a noise background and premature deterioration of working surfaces of teeths

Reduce a thickness of a lining of adjustment of height of a leading gear wheel to remove it from an axis корончатой gear wheels
Displacement to a sock
The area of a stain of contact is insufficient

Can lead скалыванию teeths from outside socks

Adjust, as in a case with lateral gearing
It is displaced to a heel
The area of a stain of contact is insufficient

Can lead скалыванию teeths from outside heels

Adjust, as in a case with superficial gearing

INSTALLATION

 PERFORMANCE ORDER

1. Establish protection and a fixing plate of back differential.
2. Establish back differential on трансмиссионный a jack and fasten their bandage tapes.

3. Establish on back differential a protector of epiploon ST 28099PA090.

4. Fill in differential a power shaft, having passed it шлицевую a part in an epiploon, then remove a protector.
5. Pressing back differential, completely fill in it power shafts.
6. Having chosen suitable position трансмиссионного a jack, fill a carving hairpin of back differential in the plug of a back cross-section beam.
7. Lift a jack and temporarily tighten самоконтрящиеся nuts of a back cross-section beam.
8. The further installation is made in an order, the return to an order of dismantle of components, - track that all fixture has been tightened with demanded effort.

9. Having finished installation, fill in differential about 0.8 l of fresh oil, having finished its level to the top mark.

 Before a tightening of a jellied stopper with demanded effort (49.0 Nanometers), grease its carving part with hermetic of type Three Bond 1105.


A — the Jellied stopper
B — the Drain stopper

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