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, check of a condition and installation of plugs and gear change rods

Design of the mechanism of a gear change

1 — the Lever of the mechanism of a gear change
2 — the Rod of a plug of inclusion of 5th transfer
3 — the Pin
4 — the Rod of a plug of inclusion of a reverse gear
5 — Stoppers of control balls
6 — Sealing washers
7 — Springs of control balls
8 — Control balls
9 — the Rod of a plug of switching of 3/4 transfers
10 — Blocking плунжеры
11 — the Rod of a plug of switching of 1/2 transfers
12 — the Plug of switching of 3/4 transfers
13 — the Plug 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 plug of inclusion of a reverse gear
18 — the Lever of inclusion of a reverse gear

Efforts of a tightening of carving connections, Nanometer

Т: 19.6

REMOVAL

 PERFORMANCE ORDER

1. Remove assemblage РКПП (see Has undressed Removal and installation трансмиссионной assemblages).
2. Remove gauges-switches of fires of a backing and neutral position РКПП (see Has undressed Removal, installation and check of a condition of gauges-switches).
3. Remove a distributing box with the lengthening case (see Has undressed Removal, service and installation of a distributing box and transmission lengthening).
4. Remove картер transmissions (see Has undressed Removal, installation and condition check картера трансмиссионной assemblages).
5. Remove assemblage 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).
6. Remove assemblage of a primary shaft (see Has undressed Removal, service, installation and adjustment of primary shaft РКПП).
7. Remove assemblage of forward differential (see Has undressed Removal, service, installation and adjustment of forward differential).

8. With the help выколотки ST 398791700 take a pin and remove a plug of inclusion of 5th transfer.

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

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

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

Pin beat out inside that it has not rested against a wall картера. At rod extraction other rods should be in neutral position.


A — the Pin
B — the Rod of a plug of switching of 3/4 transfers
C — the Plug

11. Take a pin and remove a plug 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 plug of inclusion of a reverse gear, - try not to lose a ball. Further remove a ball with a spring and take from a rod blocking плунжер. Remove a rod.
13. Remove the lever of inclusion of a reverse gear.

CHECK

 PERFORMANCE ORDER

1. Check up shaft and gear change rods on presence of signs of excessive deterioration, deformations and other mechanical damages. Defective components replace.

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

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

The list of let out plugs of switching of 1/2 transfers


3. Measure sizes of backlashes between leading gear wheels of 3rd and 4th transfers and муфтой the synchronizer. If results of measurements it do not meet requirements of Specifications (9.3 mm), address to the table resulted more low and make selection of a new plug of switching of 3/4 transfers.

A — the Leading gear wheel of 3rd transfer
B — Mufta of the synchronizer
C — the Leading gear wheel of 4th transfer

The list of let out plugs of switching of 3/4 transfers


4. Measure backlash size between a leading gear wheel of 5th transfer and муфтой the synchronizer. If the result of measurement does not correspond to requirements of Specifications (9.3 mm), address to the table resulted more low and make selection of a new plug of inclusion of 5th transfer.

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

The list of let out plugs of inclusion of 5th transfer


5. Measure sizes of backlashes between tips of rods. If results of measurements fall outside the limits admissible ranges, replace corresponding components.

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

INSTALLATION

 PERFORMANCE ORDER

1. Establish on the lever of a rod of a plug of inclusion of a reverse gear a spring, a ball and blocking плунжер in the lever, - for time fixing плунжера put on it dab консистентной greasings. Insert a rod of a plug of inclusion of a reverse gear into an aperture in its lever and fix assemblage by an external lock ring.
2. Plant in an aperture of a rod of inclusion of a reverse gear in the left part картера transmissions a ball with a spring, establish a new sealing washer, then screw and tighten a stopper.

 Ball landing is made by means of special adaptation ST 399411700.

3. Through an aperture on a back part картера transmissions pass a rod of a plug of switching of 1/2 transfers to a corresponding plug.
4. Achieve combination of apertures on a plug and a rod and insert into them a new pin.

 It is necessary to translate other rods in neutral position. Make sure that blocking плунжер is on the party of a rod of a plug of switching of 3/4 transfers. For time fixing плунжера put on it dab консистентной greasings.

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

 It is necessary to translate a reverse gear rod in neutral position. Make sure that blocking плунжер is on the party of a rod of a plug of inclusion of a reverse gear.

8. Plant a plug of inclusion of 5th transfer on the back end of the rod, achieve combination of apertures and pass in them the NEW pin.
9. Fill balls, their springs and new sealing washers in apertures of rods of switching of 1/2 and 3/4 of transfers, screw and tighten stoppers.
10. The further installation is made in an order, the return to an order of dismantle of components.

On the main page