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
   Specifications
   The mechanism of blocking of inclusion of a reverse gear - the device and a functioning principle
   Interaxal differential - the device and a functioning principle
   Removal and installation трансмиссионной assemblages
   Check of a condition and replacement of elements of support of a suspension bracket трансмиссионной assemblages
   Check of a condition and epiploon replacement
   Removal, installation and check of a condition of gauges-switches
   Removal, installation and check of a condition of the gauge of speed (VSS)
   Preparation for performance of major repairs РКПП
   Removal, service and installation of a distributing box and transmission lengthening
   Removal, service and installation of a leading gear wheel of the distributing mechanism
   Removal, service and installation of a conducted gear wheel of the distributing mechanism
   Removal, service and installation of interaxal differential
   Removal, service, installation and adjustment of assemblage of the mechanism of blocking of inclusion of a reverse gear
   Removal, installation and condition check картера трансмиссионной assemblages
   Removal, service, installation and adjustment of primary shaft РКПП
   Removal, service and installation of entrance shaft РКПП (models with an additional two-level reducer)
   Removal, service and installation of assemblage of a shaft of a leading gear wheel of the main transfer of a drive of forward wheels
   Removal, service, installation and adjustment of forward differential
   Removal, installation and check of a condition of a gear wheel of a drive of a speedometer
   Removal, installation and adjustment of an intermediate gear wheel of a reverse gear
   Removal, installation, check and adjustment of assemblage of gear wheels of a two-level reducer
   Removal, check of a condition and installation of plugs and gear change rods
   Removal, service and installation of the lever of gear change РКПП
   Removal, service and installation of the lever of switching of modes «Hi/Lo» an additional two-level reducer
   Removal, service and installation тросовой draughts of a drive of switching of modes of a two-level reducer
+ Automatic transmission
+ Coupling
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment





Removal, service, installation and adjustment of primary shaft РКПП

Design of primary shaft РКПП

1 — the Epiploon
2 — the Needle bearing
3 — the Primary shaft of transmission
4 — the Needle bearing
5 — the Leading gear wheel of 3rd transfer
6 — the Blocking ring with internal gearing (except models 2.0)
7 — the Cone of the synchronizer of 3rd transfer (except models 2.0)
8 — the Blocking ring external gearing (except models 2.0)
9 — Mufta of the synchronizer of 3/4 transfers
10 — the Nave of the synchronizer of 3/4 transfers
11 — the Sliding key of switching 3/4
12 — the Blocking ring of the synchronizer of 4th transfer
13 — the Leading gear wheel of 4th transfer
14 — the Holder of the needle bearing of a gear wheel of 4th transfer
15 — the Needle bearing
16 — the Persistent washer of a gear wheel of 4th transfer
17 — the Ball bearing
18 — the Blocking ring of the synchronizer (model 2.0)
19 — the Persistent washer of a gear wheel of 5th transfer
20 — the Holder of the needle bearing of a gear wheel of 5th transfer
21 — the Needle bearing
22 — the Back plate of a primary shaft
23 — the Leading gear wheel of 5th transfer

24 — the Blocking ring of the synchronizer of 5th transfer
25 — the Sliding key of switchings 5-5/back transfers
26 — the Plug of the synchronizer 5-5/back transfers
27 — Mufta of the synchronizer 5-5/back transfers
28 — the Blocking ring of the synchronizer of a reverse gear
29 — the Cone of the synchronizer of a reverse gear
30 — the Ball bearing
31 — the Stopper of a cone of the synchronizer
32 — the Spring lock ring
33 — the Lock washer
34 — the Counternut
35 — the Shaft of an intermediate gear wheel of a reverse gear
36 — the Pin
37 — the Intermediate gear wheel of a reverse gear
38 — the Washer

Efforts of a tightening of carving connection, Nanometer

Т: 118


Models without an additional two-level reducer

REMOVAL

 PERFORMANCE ORDER

1. Remove assemblage РКПП (see Has undressed Removal and installation трансмиссионной assemblages).
2. Remove a distributing box with the lengthening case (see Has undressed Removal, service and installation of a distributing box and transmission lengthening).
3. Remove картер transmissions.
4. Remove assemblage of a shaft of a leading gear wheel of the main transfer (see Has undressed Removal, service and installation of assemblage of a shaft of a leading gear wheel of the main transfer of a drive of forward wheels).
5. Remove assemblage of a primary shaft.

DISMANTLING

 PERFORMANCE ORDER

1. For the purpose of prevention of damage of an epiploon wind изоляционной with a tape шлицы a primary shaft, then manually take an epiploon and the needle bearing.

2. Расчеканьте also turn on from assemblage of a primary shaft a counternut.

ST1 498937000 Holder
ST2 499987003 Face key (35)

3. Remove from a primary shaft муфту the synchronizer 5-5/back transfers with a nave, blocking ring of the synchronizer and a leading gear wheel of 5th transfer with the needle bearing.

4. Remove from assemblage муфты with a nave a spring lock ring and a stopper of a cone of the synchronizer.

And — the Ball bearing
In — the Cone
With — the Blocking ring
5. By means of special adaptations (ST1 499757002 and ST2 498077400) and the press remove the ball bearing, a cone and blocking ring of the synchronizer of a reverse gear.

 Assemblage муфты with a nave is subject to replacement without fail. Муфта is in constant gearing with a nave and in case of need assemblage dismantle it is necessary to mark preliminary original position of components from each other. The ball bearing also is not subject to a reuse and should be replaced.

6. By means of special strippers ST1 899864100 and ST2 899714110 remove from a primary shaft the remained components.

CHECK

 PERFORMANCE ORDER

1. Carefully wash out all removed components.
2. Manually check up smoothness and noiselessness of rotation of bearings. Estimate degree of deterioration of bearings, check up balls and rings on presence of mechanical damages and signs of development of corrosion. Replace defective components.
3. Plugs are subject to replacement, in case of revealing of damages of a surface of sliding, signs of the excessive deterioration, threadbare sites of internal walls, etc. defects.
4. Replace gear wheels with broken, excessively worn out or a different way the damaged teeths.
5. Gear wheels are subject to replacement or restoration if the cone contacting to the blocking ring of the synchronizer has roughnesses or is damaged, and also in case of damage of internal or face surfaces.
6. Blocking rings should be checked on presence of damages and signs of deterioration of internal or face surfaces. Make sure also of absence of excessive deterioration and задиров contact surfaces of grooves under sliding keys.
7. Sliding keys are replaced in case of revealing of signs of the slightest deterioration or damage.
8. Estimate a condition of working edges of an epiploon. In case of revealing of deformations, signs of hardening of rubber or mechanical damages the epiploon is subject to replacement.
9. It will be reasonable to replace a sealing ring without dependence from its current condition.
10. Estimate also a condition of components of the mechanism of switching of transfer. In case of need make corresponding regenerative repair, replace worn out, deformed or otherwise damaged components.

ASSEMBLAGE

L models 2.0

Installation of the remained components

A — the Needle bearing
B — the Leading gear wheel of 5th transfer
C — the Blocking ring

D — Assemblage муфты the synchronizer 5-5/back transfers with a nave
E — the Lock washer
F — the Counternut


Installation of components of a drive of 3rd transfer

A — the Needle bearing
B — the Leading gear wheel
C — the Blocking ring of internal gearing

D — a synchronizer Cone
E — the Blocking ring of external gearing
F — Assemblage муфты the synchronizer with a nave


 PERFORMANCE ORDER

1. Make assemblage муфт all synchronizers with the naves. Track, that springs have been developed by locks at an angle 120 ° from each other.

2. Plant on a primary shaft a leading gear wheel of 3rd transfer, blocking ring and assemblage муфты the synchronizer of 3rd transfer with a nave, - track hit of a sliding key in a groove of a blocking ring.

3. By means of special adaptations ST1 899714110 and ST2 499877000 and the press plant on a primary shaft a holder of the needle bearing of a gear wheel of 4th transfer.

 The put landing effort should not exceed 10 кН (1 ton)!


A a bearing Holder

4. Plant on a shaft blocking ring, the needle bearing and a leading gear wheel of 4th transfer with the persistent washer, - track correctness of combination of a blocking ring and assemblage of a gear wheel with a nave with key flutes.

A — Flutes
B — To a gear wheel of 4th transfer

5. By means of special adaptations ST1 899714110 and ST2 499877000 and the press plant on a back pin of a primary shaft the ball bearing.

 The put landing effort should not exceed 10 кН (1 ton)!

6. By means of the same adaptations establish a persistent washer and a holder of the needle bearing of a gear wheel of 5th transfer, - a persistent washer develop the party equipped with flutes to a gear wheel of 5th transfer.

 The put landing effort should not exceed 10 кН (1 ton)!

7. Establish the bearing on a synchronizer cone.
8. With the help оправки ST1 499757002 establish on assemblage муфты the synchronizer 5-5/back transfers with a nave blocking ring and a cone, - do not forget to replace the ball bearing.

 Attention: the Put landing effort should not exceed 10 кН (1 ton)! Having finished installation, check up freedom of rotation of a cone.

9. Establish on assemblage муфты the synchronizer 5-5/back transfers with a nave a stopper of a cone and a spring lock ring.
10. Plant on a back pin of a primary shaft the remained components, - track hit of a sliding key in a groove of a blocking ring.
11. By means of face key ST1 499987003 and holder ST2 498937000 tighten with demanded effort (118 Nanometers) counternuts.

L models 2.5

 PERFORMANCE ORDER

1. Make assemblage муфт all synchronizers with the naves. Track, that springs have been developed by locks at an angle 120 ° from each other.
2. Plant on a primary shaft a leading gear wheel 3rd transfers blocking rings of external both internal gearing and assemblage муфты of the synchronizer of 3rd transfer with a nave, - track hit of a sliding key in a groove of a blocking ring.
3. The further assemblage is made the order similar described above for models 2.0 of l.

INSTALLATION

 PERFORMANCE ORDER

1. Plant on a forward pin of a primary shaft the needle bearing and the NEW epiploon, - for the purpose of prevention of damage of an epiploon wind шлицевую a shaft part изоляционной with a tape. Before installation grease sealing sponges of an epiploon with greasing of type Unilube #2, track, that the face surface of an epiploon was combined with a landing surface (), and the directing pin картера transmissions has got to a reception aperture in an external holder of the needle bearing.

2. The further installation is made in an order, the return to an order of dismantle of components.

ADJUSTMENT

 PERFORMANCE ORDER

By means of a measuring instrument of depth ST 498147000 measure size выступания (A) the ball bearing over a surface of the case of transmission. Proceeding from results of the spent measurement make selection approaching on back plates of a primary shaft under the table resulted more low.

 Before measurement slightly knock with a hammer with soft brisk on an end face of a primary shaft on purpose выбирания a backlash between a main thing surface картера and a mobile flange of the bearing.

Selection of a back plate of a primary shaft
The size (A), mm № details Marks
4.00 ÷ 4.13 32294AA041 1
3.87 ÷ 3.99 32294AA051 2


Models with an additional two-level reducer

REMOVAL

 PERFORMANCE ORDER

Removal procedure is similar, described above for models without a two-level reducer, with that only a difference that the primary shaft is taken together with the entrance.

DISMANTLING

 PERFORMANCE ORDER

1. Dismantling is made in the manner similar described above for models without a two-level reducer.

2. Before демонтажем components of last turn, by means of special nippers ST 899474100 remove from a primary shaft a spring lock ring.

CHECK

 PERFORMANCE ORDER

1. Carefully wash out all removed components.
2. Manually check up smoothness and noiselessness of rotation of bearings. Estimate degree of deterioration of bearings, check up balls and rings on presence of mechanical damages and signs of development of corrosion. Replace defective components.
3. Plugs are subject to replacement, in case of revealing of damages of a surface of sliding, signs of the excessive deterioration, threadbare sites of internal walls, etc. defects.
4. Replace gear wheels with broken, excessively worn out or a different way the damaged teeths.
5. Gear wheels are subject to replacement or restoration if the cone contacting to the blocking ring of the synchronizer has roughnesses or is damaged, and also in case of damage of internal or face surfaces.
6. Blocking rings should be checked on presence of damages and signs of deterioration of internal or face surfaces. Make sure also of absence of excessive deterioration and задиров contact surfaces of grooves under sliding keys.
7. Sliding keys are replaced in case of revealing of signs of the slightest deterioration or damage.
8. Estimate a condition of working edges of an epiploon. In case of revealing of deformations, signs of hardening of rubber or mechanical damages the epiploon is subject to replacement.
9. It will be reasonable to replace a sealing ring without dependence from its current condition.
10. Estimate also a condition of components of the mechanism of switching of transfer. In case of need make corresponding regenerative repair, replace worn out, deformed or otherwise damaged components.

ASSEMBLAGE

L models 2.0

Components of a primary shaft removed in last turn

A — Assemblage муфты the synchronizer with a nave
B — the Blocking ring of synchronizer Hi/Lo
C — Frictional демпфер
D — the Entrance gear wheel of a lowering mode

E — the Needle bearing
F — the Remote prorate of an entrance gear wheel of a lowering mode
G — the Ball


 PERFORMANCE ORDER

1. Plant on a primary shaft the needle bearing.
2. Plant on a forward part of a primary shaft the components listed on an illustration. Track, that the end face equipped with flutes has been developed towards an entrance gear wheel, and the sliding key of synchronizer Hi/Lo has got to a reception groove of a blocking ring.
3. By means of special adaptations ST1 499757002 and ST2 499757001 establish on штоковую section of a primary shaft the NEW spring lock ring.

 Ring selection is carried out under the table resulted more low of reasons of restriction of an axial backlash between it and a nave of synchronizers limits of a range 0.06 ÷ 0.10 mm.

Selection of a spring lock ring

№ details Thickness, mm
805025051 2.42
805025052 2.47
805025053 2.52
805025054 2.57
 805025055 2.62
805025056 2.67
805025057 2.72
805025058 2.87

L models 2.0

 PERFORMANCE ORDER

Assemblage is made similarly to the assemblage described for models without a two-level reducer taking into account additions, stated in the previous subsection.

INSTALLATION

 PERFORMANCE ORDER

Installation is made in an order, the return to an order of dismantle of components. After installation of the needle bearing on a forward pin of a shaft dock the last with target shaft of transmission.

ADJUSTMENT

 PERFORMANCE ORDER

By means of a measuring instrument of depth ST 498147000 measure size выступания (A) the ball bearing over a surface of the case of transmission. Proceeding from results of the spent measurement make selection approaching on back plates of a primary shaft under the table resulted more low.

 Before measurement slightly knock with a hammer with soft brisk on an end face of a primary shaft on purpose выбирания a backlash between a main thing surface картера and a mobile flange of the bearing.

Selection of a back plate of a primary shaft
The size (A), mm № details Marks
4.00 ÷ 4.13 32294AA041 1
3.87 ÷ 3.99 32294AA051 2

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