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 and installation of assemblage of a shaft of a leading gear wheel of the main transfer of a drive of forward wheels

Design of assemblage of a leading gear wheel of forward differential

1 — the Shaft of a leading gear wheel
2 — the Roller bearing
3 — the Washer
4 — the Persistent bearing
5 — the Needle bearing
6 — the Conducted shaft
7 — Shponka
8 — Segment шпонка
9 — the Ring of a leading gear wheel
10 — the Needle bearing
11 — the External spring lock ring
12 — the Washer
13 — the Gear ring
14 — the Conducted gear wheel of 1st transfer
15 — the Blocking ring of the synchronizer
16 — the Nave of the synchronizer of 1/2 transfers
17 — the Sliding key
18 — the Conducted gear wheel of a reverse gear
19 — the Blocking ring of the synchronizer with external gearing
20 — a synchronizer Cone
21 — the Blocking ring of the synchronizer with internal gearing

22 — the Conducted gear wheel of 2nd transfer
23 — the Plug of a conducted gear wheel of 2nd transfer
24 — the Conducted gear wheel of 3/4 transfers
25 — the Adjusting lining of a conducted gear wheel
26 — the Roller bearing
27 — the Conducted gear wheel of 5th transfer
28 — the Lock washer
29 — the Counternut
30 — the Washer
31 — the Persistent bearing
32 — the Plug of a conic gear wheel of differential
33 — the Washer
34 — the Lock washer
35 — the Counternut

Efforts of a tightening of carving connections, Nanometer

Т1: 29
Т2: 118
Т3: 265


Removal of a leading gear wheel

A — the Plug of a conic gear wheel of differential
B — the Washer №1 (25х37.5х t)
C — the Persistent bearing (25х37.5х3)
D — the Washer №1 (25х37.5х4)

E — the Needle bearing (25х37.5х20)
F — the Ring of a leading gear wheel
G — the Needle bearing (30х37х23)
H — the Persistent bearing (33х50х3)


Removal of a conducted gear wheel of 2nd transfer, blocking rings and synchronizer cone

A — the Conducted gear wheel of 2nd transfer
B — the Blocking ring of internal gearing

C — a synchronizer Cone
D — the Blocking ring of external gearing

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 (see Has undressed Removal, installation and condition check картера трансмиссионной assemblages).
4. Take assemblage of a shaft of a leading gear wheel, - in case of need hook assemblage by the hammer handle.

DISMANTLING

 PERFORMANCE ORDER

 In order to avoid damage of a conducted shaft in the course of dismantling or a partition wind with rags the end of the shaft turned to the frictional party of the persistent needle bearing the end!


1. Расчеканьте a counternut also give it by means of holder ST1 899884100, emphasis ST2 498427100 and face key ST3 899988608.

2. Remove a leading gear wheel from a leading shaft. For this purpose remove the plug of a conic gear wheel of differential, adjusting washers №1 and №2, the persistent bearing, the needle bearing, a ring of a leading gear wheel, the needle bearing and the persistent bearing.
3. By means of a press and stripper ST 498007000 remove the roller bearing and a washer.

4. Расчеканьте the second counternut also give it by means of holder ST2 899884100 and a face key (50) ST3 499987300.

5. By means of stripper ST 499857000 remove a conducted gear wheel of 5th transfer.

6. Take segment шпонку.

7. With the help оправки ST1 499757002 and stripper ST2 899714110 remove the roller bearing and a conducted gear wheel of 3/4 transfers.

8. Take a straight line шпонку.
9. Remove a conducted gear wheel of 2nd transfer, blocking ring of internal gearing, a cone of the synchronizer and blocking ring of external gearing.
10. With the help оправки ST1 499757002 and stripper ST2 899714110 remove a conducted gear wheel of 1st transfer, the plug of a gear wheel of 2nd transfer and assemblage of a gear wheel with a nave.

 Assemblage of a gear wheel with a nave should be in case of need replaced. The gear wheel 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.

11. Remove a gear ring of a conducted gear wheel of 1st transfer.

CHECK

 PERFORMANCE ORDER

1. Check is similar to the corresponding operations described in Section Removal, service, installation and adjustment of primary shaft РКПП.

 Check of smoothness of rotation of the ball bearing established from the back party of assemblage of a shaft of a leading gear wheel should be made before removal of components of a shaft, the bearing pretightness otherwise will be eliminated!


And — Assemblage of a shaft of a leading gear wheel of the main transfer
In — the Ball bearing

2. Besides, check up backlash size (A) between trailer surfaces of the blocking ring wrung out to a cone and gear wheels. If the result of measurement makes less than 0.5 1.0 mm, replace a ring.

ASSEMBLAGE

Installation муфты and assemblages of a gear wheel with the plug

A — To a gear wheel of 1st transfer
B — To a gear wheel of 2nd transfer

C — the surfaces Deduced on one level
D — Steps


 PERFORMANCE ORDER

1. Watching combination of landing labels, establish муфту and assemblage of a gear wheel with a nave.
2. Establish a washer and a spring lock ring, then establish a gear ring of a conducted gear wheel of 1st transfer.
3. Plant on a conducted shaft a conducted gear wheel of 1st transfer, blocking ring of the synchronizer of 1st transfer and assemblage of a gear wheel with a nave, - track, that assemblage of a gear wheel with a nave has appeared is developed in the correct image, and the sliding key has got to a groove of a blocking ring.

4. By means of a press both оправок ST1 499277200 and ST2 499587000 plant on a conducted shaft the plug of a conducted gear wheel of 2nd transfer, - the shaft end wind with rags (the prevention in the beginning of subsection "Dismantling" see). At press installation track correctness of combination of oil apertures of a shaft and the plug.

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

5. Plant on a conducted shaft a conducted gear wheel of 2nd transfer, an external blocking ring, the synchronizer cone, blocking ring of external gearing and a sliding key.
6. The further assemblage is made in an order, the return to an order of dismantle of components. The effort of a tightening of the second counternut makes 265 Nanometers.

7. After зачеканивания counternuts in two points by means of a steelyard check up the initial moment проворачивания the roller bearing, - the result of measurement should not fall outside the limits a range 0.1 1.5 Н.

8. Track correctness of installation of the roller bearing, the aperture under a pin in its external holder is located asymmetrically.

And — the Bearing
In — the Aperture under a pin

Adjustment of a pretightness of the persistent bearing

 PERFORMANCE ORDER

1. Make selection of an adjusting washer №1 so that the backlash H approximately seemed zero. Establish usual (18.3х30х4) and lock (18х30х2) washers, then screw the first counternut (18х13.5) and tighten it with effort of 118 Nanometers.

2. Remove emphasis ST2 498427100 and measure initial effort проворачивания the bearing.
3. If the result of measurement falls outside the limits an admissible range (54 25 Nanometers), address to the table resulted more low and pick up a new adjusting washer №1, then repeat check.

Selection of an adjusting washer №1

№ details Thickness, mm
803025051 3.925
803025052 3.950
803025053 3.975
803025054 4.000
803025055 4.025
803025056  4.050
803025057 4.075

4. If to achieve satisfactory result by washer selection № 1 it is not possible, address to the table resulted more low and make побор an adjusting washer №2 and repeat the operations described in paragraphs with 1 on 3.

 For increase in initial effort проворачивания and backlash sizes H it is necessary to use thicker adjusting washer №2, otherwise - more thin.


And — the Washer № 1
In — the Washer № 2

Selection of an adjusting washer №2

№ parts Thickness, mm
803025059 3.850
803025054 4.000
 803025058 4.150

5. Once again check up initial effort проворачивания the bearing, then зачеканьте a counternut in four points.

INSTALLATION

 PERFORMANCE ORDER

1. Remove assemblage of forward differential.

2. Achieve combination of numerical labels of the leader of main transfer conducted gear wheels to transfer. The top number on a leading gear wheel serves for its combination with a well-aimed conducted gear wheel, bottom - for selection of an adjusting lining. Absence of number corresponds to its zero value.

3. Establish assemblage of a leading gear wheel of the main transfer without an adjusting washer in the right section of the main thing картера transmissions and tighten bolts of fastening of the bearing.

4. Prepare for work a measuring instrument of a leading gear wheel (ST 499917500): ослабьте two bolts also adjust a measuring instrument so that at deducing 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. Establish a measuring instrument, having inserted its pin into a reception aperture in the transmission case.

6. Shifting a scale of a measuring instrument a finger, consider the indication in a point when where it will be combined with a face surface of a leading gear wheel.

A — Deduce a backlash in a zero in the absence of an adjusting lining

7. The demanded thickness of an adjusting lining is defined by addition to indications of a measuring instrument of value of the numerical marks put down on a conducting gear wheel in case before a numerical label on a leading gear wheel the sign + is put down, or a way subtracting the same number if before it the sign is put down -.
8. Try to achieve the maximum approach to demanded value by selection of a combination from 1 to 3 adjusting linings. The list of let out linings is given in the table resulted more low.

Thickness of let out adjusting linings of a leading gear wheel

№ details Thickness, mm
32295AA031 0.150
32295AA041 0.175
32295AA051 0.200
32295AA061 0.225
32295AA071 0.250
 32295AA081 0.275
32295AA091 0.300
32295AA101 0.500

9. Establish differential assemblage.
10. Establish assemblages of a primary shaft and a shaft of a leading gear wheel, - track, that at displacement of both assemblages against the stop forward the backlash between them completely got out. Check up serviceability of functioning of plugs of a gear change (1/2 3/4 and 5), - муфта and a conducted gear wheel of a reverse gear should settle down on the centre of assemblages of the synchronizers.
11. The further installation is made in an order, the return to an order of dismantle of components.

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