Subaru Forester

1997-2005 of release

Repair and car operation



Subaru Forester
+ Cars Subaru Forester
+ The maintenance instruction
+ Routine maintenance
+ The engine
+ Systems of cooling, heating
+ The power supply system and release
+ Engine electric equipment
+ Control systems of the engine
+ Gear change box
- Coupling, трансмиссионная a line
   Specifications
   Coupling - the general information and check of a condition of components
   Removal, check of a condition of components and installation of the main cylinder of coupling
   Removal and installation of the executive cylinder of coupling
   Removal of air from a hydraulic path of a drive of deenergizing of coupling
   Forward power shafts - the general information
   Removal, service and installation of forward power shafts
   Removal and installation of assemblage of a rotary fist, service ступичной assemblages
   Back power shafts - the general information
   Removal, service and installation of back power shafts
   Removal, service and installation of a back nave
   Back differential - the general information
   Removal and installation карданного a shaft
   Removal and installation of a flange of a leading gear wheel of differential and epiploon
   Removal and installation of back differential
   Differential major repairs
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
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Differential major repairs

VA-type differential

Preparation for dismantling

 PERFORMANCE ORDER

1. Transfer differential on the assembly stand (398217700).
2. Remove a back cover.
3. Study the form of contact stains of teeths of gear wheels (the gear change Box see the Head).
4. With the help циферблатного a measuring instrument плунжерного type define люфт gearings of a conducted gear wheel, - the rating value makes 0.10 0.15 mm.
5. Estimate size of palpation of a conducted gear wheel, - the result of measurement should not exceed 0.05 mm.
6. Measure and write down a twisting moment проворачивания a leading gear wheel.
7. Mark adjusting полоджения holders of lateral bearings.


Dismantling

Design of back differential of T-type (for VA-type differential the similar picture takes place)

1  — the  Washer of adjustment of a pretightness
2  — the  Remote plug of adjustment of a pretightness
3  — the  Adjusting washer of a leading gear wheel
4  — the  Leading gear wheel
5  — the  Conducted gear wheel
6  — the  Persistent washer
7  — the  Lateral gear wheel
8  — the  Satellite
9  — the  Back cover
10  — the  Lock pin
11  — the  Back bearing

12  — the  Casing of the holder of differential
13  — the  Forward bearing
14  — the  Axis of satellites
15  — a  differential Box
16  — the  Lateral bearing
17  — the  Holder of the lateral bearing
18  — the  Nut of fastening of a leading gear wheel
19  — the  Connecting flange
20  — the  Epiploon
21  — the  Directing bearing
22  — the  Remote plug of the directing bearing


 PERFORMANCE ORDER

1. Merge oil from differential.
2. Remove a back cover.
3. Mark positions of nuts of the right and left lateral bearings (holders of power shafts).
4. Remove lock plates.
5. By means of a suitable wrench remove holders of power shafts.
6. Take assemblage of differential of their casing of the holder.
7. By means of a stripper remove from holders of shaft of a holder of lateral bearings.
8. Take lateral bearings from a casing of the holder of differential.
9. Remove a conducted gear wheel.
10. Расчеканьте a lock pin of an axis of satellites.
11. Beat out a pin from outside a flange.
12. Take an axis of satellites, satellites, lateral gear wheels and persistent washers, - try to put removed components as their installation in assemblage.
13. Give a nut of fastening of a leading gear wheel.
14. By means of a suitable stripper dismantle a connecting flange.
15. Выпрессуйте a leading gear wheel from a casing of the holder of differential in gathering with an internal holder of the back bearing, the remote plug of the bearing and an adjusting washer.
16. Take an epiploon of a connecting flange.
17. By means of brass выколотки dismantle directing bearing.
18. Remove the forward bearing.
19. Dismantle a holder of the forward bearing.


Cleaning and check of a condition of components

 PERFORMANCE ORDER

1. Carefully wash out all removed components solvent.
2. Check up a condition of teeths of leading and conducted gear wheels of differential, - in case of detection of cracks, falcons and other mechanical damages replace both gear wheels.
3. Estimate degree of deterioration of bearings, check up them on presence of traces of an overheat and jamming signs.
4. Estimate degree of deterioration of working surfaces of persistent washers.
5. Defective components replace.


Assemblage and adjustment

Installation of a single (technological) shaft


Measurement of adjusting height of a leading gear wheel of differential


 PERFORMANCE ORDER

1. Запрессуйте in a differential casing external holders of forward and back bearings.
2. Establish in a casing of differential a single (technological) shaft (498447150) shaft.
3. Plant on a single shaft the remote plug and a washer of adjustment of a pretightness, the forward bearing, the single (technological) plug (32285АА000), a connecting flange and a washer, screw a nut, - an epiploon do not establish. Turn assemblage manually for усадки components.
4. Tighten a nut with demanded effort. The twisting moment measured by means of a dynamometer проворачивания a technological shaft for new bearings should not fall outside the limits a range 1.3 3.3 кГс, - in case of need pick up others adjusting a washer and the remote plug. Plugs are issued in a range of thickness from 52.30 to 53.30 mm with step of 0.05 mm (numbers of details from 32288АА040 to 32288АА090), washers - in a range from 1.50 till with step of 0.012 mm (numbers of details from 38386АА000 to 38386АА110).
5. Without removing a single shaft, establish a measuring instrument of height of a conducted gear wheel (498505501). With the help probeа лезвийного type measure backlash size “N” between an end face of a head of a single shaft and a height measuring instrument. Using the formula resulted on an illustration, define a demanded thickness of an adjusting washer.
6. Dismantle a single shaft and a height measuring instrument. Adjusting washers are issued in a range of thickness from 0.150 to 0.275 mm with step of 0.025 mm (numbers of details from 32295АА200 to 32295АА250), - plant a washer of a demanded thickness on a shaft of a leading gear wheel.
7. Напрессуйте on a shaft the back bearing.
8. Fill assemblage of a leading gear wheel in a casing of the holder of differential.
9. Establish picked up earlier remote plug and a washer of adjustment of the pretightness, directing bearing, an epiploon and a connecting flange. Screw a fixing nut and tighten it with demanded effort.
10. Establish on the regular places in a box of differential satellites, lateral gear wheels and persistent washers. Fill an axis of satellites and achieve combination of apertures under installation of a blocking pin.
11. The backlash size between back surfaces of lateral gear wheels and walls of a box of differential (axial люфт gear wheels) should not fall outside the limits a range 0.05 0.15 mm and is regulated by selection of persistent washers corresponding on a thickness. Washers of next thickness are issued: 0.93 0.95 mm, 0.98 1.00 mm, 1.00 1.03 mm and 1.03 1.05 mm.
12. Establish a blocking pin of an axis of satellites and fix it from both parties.
13. Grease трансмиссионным with oil working and persistent surfaces of gear wheels and check up smoothness of their rotation.
14. Establish on the regular place on a differential box a conducted gear wheel. Screw the bolts equipped with new lock washers and tighten them in a diagonal order.
15. Запрессуйте in apertures in a differential box internal holders of lateral bearings, external holders plant in apertures of holders of power shafts.
16. Plant in the reception nests new epiploons, having filled cavity greasing between their sealing sponges.
17. Operating in an order, the return to an order of dismantle of components, plant assemblage of a box of differential in a casing of the holder. Screw holders of power shafts (without sealing rings) to an easy emphasis in bearings.
18. Make sure of completeness of input in gearing of the leader and conducted gear wheels of differential.
19. Turn out on one and a half tooth the holder of the right power shaft (from outside conducted gear wheel), the holder of the left shaft screw on 2 teeth.
20. Measure size люфта gearings of leading and conducted gear wheels. If the result of measurement falls outside the limits an admissible range (0.10 0.15 mm), repeat procedure of adjustment of holders.
21. Check up the form of stains of contact of gear wheels (the gear change Box see the Head). In case of need repeat adjustments.


T-type differential

Preparation for dismantling

 PERFORMANCE ORDER

1. Transfer differential on the assembly stand (398217700).
2. Merge oil from differential.
3. Remove a back cover.
4. Study the form of contact stains of teeths of gear wheels (the gear change Box see the Head).
5. With the help циферблатного a measuring instrument плунжерного type define люфт gearings of a conducted gear wheel, - the rating value makes 0.10 0.20 mm.
6. Estimate size of palpation of a conducted gear wheel, - the result of measurement should not exceed 0.05 mm.
7. Measure and write down a twisting moment проворачивания a leading gear wheel.
8. Mark adjusting полоджения holders of lateral bearings.


Dismantling

Design of back differential of T-type (for VA-type differential the similar picture takes place)

1  — the  Washer of adjustment of a pretightness
2  — the  Remote plug of adjustment of a pretightness
3  — the  Adjusting washer of a leading gear wheel
4  — the  Leading gear wheel
5  — the  Conducted gear wheel
6  — the  Persistent washer
7  — the  Lateral gear wheel
8  — the  Satellite
9  — the  Back cover
10  — the  Lock pin
11  — the  Back bearing

12  — the  Casing of the holder of differential
13  — the  Forward bearing
14  — the  Axis of satellites
15  — a  differential Box
16  — the  Lateral bearing
17  — the  Holder of the lateral bearing
18  — the  Nut of fastening of a leading gear wheel
19  — the  Connecting flange
20  — the  Epiploon
21  — the  Directing bearing
22  — the  Remote plug of the directing bearing


 PERFORMANCE ORDER

1. Remove a back cover.
2. Mark positions of holders of the right and left lateral bearings.
3. Turn out fixing bolts and by means of a stripper dismantle holders of bearings.
4. Take assemblage of differential from a casing of the holder, - try not to damage teeths of a conducted gear wheel.
5. By means of a stripper remove from holders of a holder of lateral bearings.
6. In need of performance of their replacement dismantle by means of a stripper lateral bearings.
7. Remove a conducted gear wheel.
8. Расчеканьте a lock pin of an axis of satellites.
9. Beat out a pin from outside a flange.
10. Take an axis of satellites, satellites, lateral gear wheels and persistent washers, - try to put removed components as their installation in assemblage.
11. Give a nut of fastening of a leading gear wheel.
12. By means of a suitable stripper dismantle a connecting flange.
13. Выпрессуйте a leading gear wheel from a casing of the holder of differential in gathering with an internal holder of the back bearing, the remote plug of the bearing and an adjusting washer.
14. Take an epiploon of a connecting flange.
15. By means of brass выколотки dismantle directing bearing.
16. Remove the forward bearing.
17. Dismantle a holder of the forward bearing.


Cleaning and check of a condition of components

 PERFORMANCE ORDER

1. Carefully wash out all removed components solvent.
2. Check up a condition of teeths of leading and conducted gear wheels of differential, - in case of detection of cracks, falcons and other mechanical damages replace both gear wheels.
3. Estimate degree of deterioration of bearings, check up them on presence of traces of an overheat and jamming signs.
4. Estimate degree of deterioration of working surfaces of persistent washers.
5. Defective components replace.


Assemblage and adjustment

 PERFORMANCE ORDER

1. Запрессуйте in a differential casing external holders of forward and back bearings.
2. Establish in a casing of differential a single (technological) shaft (398507702) shaft.
3. Plant on a single shaft the remote plug and a washer of adjustment of a pretightness, the forward bearing, the single (technological) plug (398507703), a connecting flange and a washer, screw a nut, - an epiploon do not establish. Turn assemblage manually for усадки components.
4. Tighten a nut with demanded effort. The twisting moment measured by means of a dynamometer проворачивания a technological shaft for new bearings should not fall outside the limits a range 2.0 2.9 кГс, - in case of need pick up others adjusting a washer and the remote plug. Plugs are issued in a range of thickness from 56.20 to 57.20 mm with step of 0.2 mm (numbers of details from 383695201 to 383695206), washers - in a range from 2.310 to 2.590 with step of 0.020 mm (numbers of details from 383845200 to 383715200).
5. Establish under the back bearing before the removed adjusting gear wheel and a measuring instrument of height of a conducted gear wheel (398507701). With the help probeа лезвийного type measure backlash size “N” between an end face of a head of a single shaft and a height measuring instrument. Using the formula resulted on an illustration, define a demanded thickness of an adjusting washer.
6. Dismantle a single shaft and a height measuring instrument. Adjusting washers are issued in a range of thickness from 3.190 to 3.660 mm with step of 0.03 mm, - plant a washer of a demanded thickness on a shaft of a leading gear wheel.
7. Напрессуйте on a shaft the back bearing.
8. Fill assemblage of a leading gear wheel in a casing of the holder of differential.
9. Establish picked up earlier remote plug and a washer of adjustment of a pretightness.
10. Establish the forward bearing.
11. Establish the remote plug, directing bearing, an epiploon and a connecting flange. Screw a fixing nut and tighten it with demanded effort.
12. By means of a spring dynamometer measure and write down a twisting moment проворачивания a leading gear wheel.
13. Establish on the place on a differential box a conducted gear wheel. Screw the bolts equipped with new lock washers and tighten them in a diagonal order.
14. Establish on the regular places in a box of differential satellites, lateral gear wheels and persistent washers. Fill an axis of satellites and achieve combination of apertures under installation of a blocking pin.


Measurement of width of the lateral bearing of differential

1  — the  Load pulley
2  —  Calibre
3  — the  Lateral bearing

 


 PERFORMANCE ORDER

1. At installation of new lateral bearings measure their width by means of a load pulley (398227700), - before the measurement beginning some times turn the bearing manually. The nominal width makes 20.00 mm, - at an appreciable deviation pick up other bearing.
2. Запрессуйте internal holders of lateral bearings in a differential box, external - in holders of bearings.
3. Establish new sealing rings. Slightly grease sealing sponges of an epiploon.
4. Pick up adjusting washers of holders of the left and right lateral bearings. In the absence of marks consider its zero. By selection of washers of a demanded thickness (see the table), adjust backlash size between a box of differential and back walls of lateral bearings, - the backlash size should not fall outside the limits an admissible range (0.10 0.20 mm).


Washers of adjustment axial люфта lateral gear wheels of differential

№ details

Thickness, mm

383475201
0.20
383475202
0.25
383475203
0.30
383475204
0.40
383475205
0.50

Holders of lateral bearings are established маркировочными by arrows to the top fixing bolt

1  —  Marks in the form of an arrow
2  — the  Holder of the bearing


 PERFORMANCE ORDER

1. Establish holders of bearings in a casing of the holder of differential (маркировочными arrows to the top bolt).
2. Tighten fixture with demanded effort.
3. Establish a blocking pin of an axis of satellites and fix it from both parties.
4. Grease трансмиссионным with oil working and persistent surfaces of gear wheels and check up smoothness of their rotation.
5. Plant in the reception nests new epiploons, having filled cavity greasing between their sealing sponges.
6. Operating in an order, the return to an order of dismantle of components, plant assemblage of a box of differential in a casing of the holder.
7. Measure size люфта gearings of leading and conducted gear wheels. If the result of measurement falls outside the limits an admissible range (0.10 0.20 mm), make corresponding updating by replacement of adjusting washers, - establish in one party a washer of a smaller thickness, with another, - on the same size большей thickness (the total thickness of both washers should remain invariable!).
8. By means of a spring dynamometer define twisting moment size проворачивания a leading gear wheel and compare it to result of the previous measurement. If the moment exceeds value 0.30 1.1 кГс, make selection of new adjusting washers of holders of lateral bearings.
9. Define size of palpation of the back party of a conducted gear wheel, - the result of measurement should not exceed value of 0.05 mm.
10. Check up smoothness проворачивания gear wheels.
11. In case of replacement of washers repeat all checks.
12. Check up the form of stains of contact of gear wheels (the gear change Box see the Head), in case of need repeat adjustments.