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
   - 5-step manual box of a gear change (РКПП)
      The general information
      Removal and installation of a box of a gear change
      Preparation for performance of repair work on restoration РКПП
      Dismantling and assemblage of a distributing box, service of components
      Major repairs РКПП of all-wheel drive models
      Service of a drive of a gear change
      Service of the lever of switching of a distributing box
   + 4-step automatic transmission (АТ)
+ Coupling, трансмиссионная a line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
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Dismantling and assemblage of a distributing box, service of components

Removal, service and installation of a distributing box and lengthening РКПП (models with a constant drive on all wheels)

Removal

Design of a distributing box and lengthening РКПП (models with a constant full drive)

1  — the  Cover картера a distributing box
2  — the  Sealing lining
3  — the  Epiploon
4  — the  Sealing lining
5  — the  Gauge-switch of a choice of neutral transfer
6  — the  Gauge-switch of fires of a backing
7  —  Carter of a distributing box
8  — the  Sealing lining
9  —  Lubricant knot

Details of the safety mechanism of inclusion of a reverse gear (10 22)

10  — the  Ball
11  — the  Spring
12  — the  Sealing lining
13  —  Zaglushka
14  — the  Internal lock ring
15  — the  Persistent plate (steals up at adjustment)
16  — the  Returnable spring of a cam
17  — the  Returnable spring of the platen
18  — the  Cam

19  —  Bring down a cam (steals up at adjustment)
20  — the  Sealing ring
21  — the  Adjusting lining (steals up at adjustment)
22  — the  Sleeve
23  — the  Adjusting lining (steals up at adjustment)
24  — the  Ball bearing
25  — the  Conducted gear wheel of intermediate transfer of a drive of back wheels
26  — the  Ball bearing
27  — the  Epiploon
28  — the  Arm of the mechanism of a gear change
29  — the  Cover of lengthening РКПП
30  — the  Sealing lining
31  —  Lubricant knot
32  — the  Lock ring with internal diameter 30 mm (steals up at adjustment)
33  — the  Sealing lining
34  — the  Ball bearing
35  — the  Lock ring with external diameter 72 mm (steals up at adjustment)
36  — the  Leading gear wheel of intermediate transfer
37  —  Carter of lengthening


 PERFORMANCE ORDER

1. Disconnect all brought to РКПП electroconducting.
2. Uncover картера a distributing box.
3. Turn out the screw of fastening of the lever of switching to a gear change rod.
4. Remove a distributing box with lengthening.

Dismantling of a distributing box

Extraction of internal components of a distributing box

1  —  Carter of a distributing box
2  —  Interaxal differential and a shaft of a conducted gear wheel of intermediate transfer of a drive of back wheels
3  — the  Adjusting washer
4  — the  Adjusting washer
5  —  Assemblage of lengthening РКПП

 


 PERFORMANCE ORDER

1. Separate assemblage of lengthening РКПП from картера boxes.
2. Take a conducted shaft in gathering with a gear wheel of intermediate transfer of a drive of back wheels and interaxal differential.
3. Remove an adjusting washer of a conducted shaft of intermediate transfer of a drive of back wheels.
4. Remove an adjusting washer of interaxal differential.

Details of installation of the lever of switching and components of the safety mechanism of inclusion of a reverse gear

1  — the  Distributing box
2  — the  Screw of fastening of the lever of switching to a rod
3  — the  Sleeve of the safety mechanism
4  — the  cam Platen
5  — the  Cover картера a distributing box

 


The arrangement scheme on картере a distributing box of gauges-switches, the safety mechanism of inclusion of a reverse gear and a lead of the lever of switching

1  — the  Gauge-switch of a choice of neutral transfer
2  — a  lever Lead
3  —  Zaglushka
4  — the  Safety mechanism
5  — the  Gauge-switch of fires of a backing
6  —  Lubricant knot

 


 PERFORMANCE ORDER

1. Liberate the lever of switching and remove its lead.

Before lever removal disconnect the gauge-switch of inclusion of neutral transfer.

2. Turn out заглушку and take a spring and a ball of the safety mechanism of inclusion of a reverse gear.

Design of safety fur of inclusion of a reverse gear

1  — the  Sealing ring
2  — the  Sleeve
3  — the  cam Platen (steals up at adjustment)
4  — the  Returnable spring of the platen
5  — the  Cam
6  — a  cam Spring
7  — the  Persistent plate (steals up at adjustment)
8  — the  Lock ring

 


 PERFORMANCE ORDER

1. Remove the safety mechanism. Having hooked a screw-driver, take established with the face party of a sleeve a lock ring. Disassemble the safety mechanism.

The deformed or weakened lock ring is subject to replacement!

2. Turn out the gauge-switch of fires of a backing.
3. Remove lubricant knot.

Dismantling of lengthening РКПП

 PERFORMANCE ORDER

1. Uncover the extension piece and an arm of the mechanism of a gear change.
2. Remove lubricant knot.
3. Remove a lock ring.
4. Liberate a shaft with a leading gear wheel of intermediate transfer from an internal holder of the ball bearing.
5. Remove a lock ring from the extension piece case, then take the bearing.
6. Take from the case of lengthening an epiploon.

The bearing it is necessary to take from картера lengthenings only in the event that it requires replacement.

The removed bearing and epiploon are subject to replacement without fail!


Assemblage of lengthening РКПП

 PERFORMANCE ORDER

1. Establish the ball bearing in картер lengthenings and pick up a lock ring so that a backlash between it and an external holder of the bearing made 0 0.15 mm. Lock rings are issued by thickness 1.78, 1.90 and 2.02 mm ( 72 mm).
2. Запрессуйте a shaft of a leading gear wheel of intermediate transfer to the bearing.
3. Plant on a shaft a lock ring. Measure backlash size between a ring and an internal holder of the bearing. The rating value makes 0 0.15 mm. Lock rings are issued by thickness 1.53, 1.65 and 1.77 mm ( 30 mm).
4. Establish lubricant knot, - track correctness of an arrangement of knot in the lengthening case.
5. Establish a cover of lengthening and an arm of the mechanism of a gear change.
6. Plant in the lengthening case a new epiploon.

Assemblage of a distributing box

The scheme of an arrangement of components of the safety mechanism at assemblage

1  — the  Cam
2  — a  cam Spring
3  — the  Lock ring
4  — the  Persistent plate

 


 PERFORMANCE ORDER

1. Assemblage is made as it should be the return to an order of dismantle of components. It is necessary to give special attention to the moments listed more low.
2. At assemblage of the safety mechanism of inclusion of transfer of a backing track, that the unbent end of a spring has got to a reciprocal cut in a cam. Establish the cam platen, a cam, a returnable spring and a cam spring in a sleeve of the safety mechanism. Fix the unbent end of a spring of a cam for a persistent plate. Develop a cam so that its cut has seemed in a cut of a plate and, keeping a cam in this position, fill a persistent plate in a sleeve, then fix components by means of a lock ring. Plant in an external flute on a sleeve surface a new sealing ring (34.5х1.5).
3. Make sure of correctness of assemblage of the safety mechanism. Check up, that cut of the platen of a cam remained is combined with a cut in a sleeve. Manually check up smoothness of a course of a cam at it поворачивании, - if at release the cam does not come back in a starting position, replace its spring. Shift assemblage of a cam with the platen towards a persistent plate, then release, - if at release the cam does not come back in a starting position, replace its spring. If the platen does not come back, check up a condition of an internal surface of a sleeve, - in the absence of defects replace a returnable spring. Pick up approaching in the sizes the platen of a cam and a persistent plate.
4. Establish the gear change lever in a distributing box with the forward party, filling a lever lead in a cut of the safety mechanism of inclusion of transfer of a backing. Having inserted a lever axis into a lead aperture, continue to push it until the axis end will not seem from a back wall of a distributing box.
5. Grease трансмиссионным with oil components of the mechanism of a gear change.
6. Make sure of correctness of installation and serviceability of a condition of all epiploons.


Connection of a distributing box with lengthening РКПП


Assemblage of lengthening with a distributing box

1 —  Interaxal differential and a shaft of a leading gear wheel of intermediate transfer
2  — the  Adjusting washer (steals up at adjustment)
3  — the  Adjusting washer (steals up at adjustment)
4  —  Carter of a distributing box
5  —  lengthening of a distributing box

 


Size measurement выступания differential over a plane картера a distributing box

1  —  Interaxal differential
2  —  Carter

 


Measurement of depth of landing of a leading gear wheel of intermediate transfer in the lengthening case

1  — the  Shaft of a leading gear wheel of intermediate transfer
2  —  Lengthening

 


 PERFORMANCE ORDER

1. Establish interaxal differential and a leading gear wheel of intermediate transfer with shaft in картер a distributing box /
2. Measure size And выступания differential over a plane картера.
3. Measure depth In landings of a shaft of a leading gear wheel of an intermediate gear wheel in lengthening of a distributing box.
4. Calculate size of a backlash With under the formula: With = In - And + 0.24 (mm), where 0.24 mm - a thickness of a lining.

Proceeding from result of the made calculation, pick up a demanded adjusting washer:

 Backlash With, mm

Adjusting washer of interaxal differential

№ details

Thickness, mm

1.60 1.74 38965АА090 1.25
1.90 2.04 38965АА090 1.40
1.90 2.04 38965АА100 1.55
2.05 2.19 38965АА110 1.70
2.20 2.40 38965АА120 1.85

The backlash size between an adjusting washer of differential and the persistent bearing makes 0.35 0.55 mm.

Installation of an adjusting washer on interaxal differential

1  — the  Adjusting washer
2  — the  differential Case

 


Height of landing of the bearing of a shaft of a conducted gear wheel of intermediate transfer over an interfaced surface картера a distributing box

1  — the  Shaft of a conducted gear wheel
2  — the  Bearing
3  —  Carter of a distributing box

 


Selection of an adjusting washer of the bearing of a conducted shaft of intermediate transfer of a drive of back wheels

1  —  Lengthening of a distributing box

 


 PERFORMANCE ORDER

1. Establish a washer on interaxal differential.
2. Now pick up an adjusting washer of the bearing of a conducted shaft of intermediate transfer of a drive of back wheels: measure height W of landing of the bearing of a shaft of an intermediate gear wheel over an interfaced surface картера a distributing box.
3. Measure size Х.
4. Count up size of backlash Y under the formula: Y = Х - W + 0.24 (mm), where 0.24 mm - a thickness of a lining.

Proceeding from result of the made calculation pick up an adjusting washer:

 Backlash Y, mm

Adjusting washer of interaxal differential

№ details

Thickness, mm

1.60 1.74 803052021 0.50
1.75 1.89 803052022 0.75
1.90 2.04 803052023 1.00

The backlash size between an adjusting washer and the bearing makes 0.05 0.30 mm.

 PERFORMANCE ORDER

1. Establish a washer on a shaft.
2. Establish lengthening assemblage on картер a distributing box.

Installation and adjustment

 PERFORMANCE ORDER

1. Establish assemblage of a distributing box with lengthening on a transmission.
2. Put on a lead of the lever of switching the lever and fix its fixing screw.

Track, that the lead has got to a cut of the safety mechanism of inclusion of a reverse gear!

3. Include 3rd transfer. The switching lever should move freely enough towards inclusion of 1/2 transfers, however, thanks to the effort developed by a returnable spring shows appreciable resistance at attempt of inclusion of a reverse gear (against the stop in the terminator).
4. Adjust effort of resistance of the lever to reverse gear inclusion so that only ненамного surpassed resistance at inclusion of 1/2 transfers. Adjustment is made by a selection of the adjusting lining established between картером of a distributing box and a sleeve of the safety mechanism, - turn out bolts of fastening of the safety mechanism.

Try not to damage at selection of a lining a sealing ring! Linings of two standard sizes are issued: № 32190АА000, thickness of 0.15 mm and № 32190АА010, thickness of 0.30 mm.

At lining removal neutral position of the switch comes nearer to a point of inclusion of a backing, at addition - to a point of inclusion of 1/2 transfers.

If to achieve demanded result by lining selection it is not possible, replace the cam platen in the safety mechanism. At a platen end face there are identification marks by means of which it is easy to define its dimensional characteristics:


The cam platen

№ details
32188АА020
Label
AND
The note
Neutral position of the switch comes nearer to a point of inclusion of 1st transfer
№ details
32188АА002
Label
In/is absent
№ details
32188АА030
Label
WITH
The note
Neutral position of the switch comes nearer to a point of inclusion of a reverse gear

 PERFORMANCE ORDER

1. Make sure of serviceability of inclusion of 5th and back transfers.
2. Check up, whether the lever in neutral position at deenergizing of transfer of a backing comes back, - if is not present, pick up a persistent plate of the safety mechanism corresponding in the sizes (address to the table):


Persistent plate

деталои

Marks

Corner

Notes

32189AA020
0
34
The switch is displaced more close to position of inclusion of 5th transfer
32189AA020
1
34
The switch is displaced more close to position of inclusion of 5th transfer
32189AA020
2
34
The standard
32189AA030
3
37
The switch is displaced more close to position of inclusion of a reverse gear
32189AA040
4
40
The switch is displaced more close to position of inclusion of a reverse gear

Removal, service and installation of a distributing box and lengthening РКПП (models with a disconnected drive on all wheels)

Removal

Design of a distributing box and lengthening РКПП (models with a disconnected drive of back wheels)

1  — the  Cover картера a distributing box
2  — the  Sealing lining
3  — the  Spring pin
4  — an  inclusion Plug муфты a drive of back wheels
5  —  Lubricant knot
6  — the  Ball
7  — the  Spring
8  — the  inclusion Platen муфты a drive of back wheels
9  — the  External executive lever of inclusion of a drive
10  — the  Finger
11  — the  Spring pin
12  —  the Clamp
13  — the  Epiploon
14  — the  Sealing lining
15  —  Carter of a distributing box
16  — the  Gauge-switch of fires of a backing
17  — the  Gauge-switch of a choice of neutral transfer
18  — the  Epiploon
19  — the  Holder of the needle bearing
20  — the  Rod of a plug of inclusion of a drive of back wheels

21  — the  Epiploon
22  — a  lengthening Shaft
23  — the  Sealing lining
24  —  Lengthening
25  — the  Sealing lining
26  — the  Gauge-switch of a full drive
27  — the  Epiploon
28  —  Pylnik
29  — the  Nut
30  — the  Lock washer
31  — the  Ball bearing
32  — the  Persistent washer
33  — the  Plug
34  — the  Conducted gear wheel of intermediate transfer
35  — the  Nave муфты
36  —  Mufta of inclusion of a back drive
37  — the  Remote washer
38  — the  Lock ring
39  — the  Bearing


Details of connection of a drive of inclusion

1  — the  inclusion Platen муфты a drive of back wheels
2  — the  Spring pin (5.2 х 8)
3  — a  cable Tip
4  — the  Finger
5  —  the Clamp
6  — the  External executive lever

 


 PERFORMANCE ORDER

1. The design of assemblage of a distributing box and lengthening РКПП is presented on an accompanying illustration.
2. Disconnect all brought to РКПП electroconducting.
3. Выпрессуйте the spring pin (2) connecting the external executive lever (9) with platen муфты of a drive of back wheels also remove the lever.
4. Remove a clamp (5) and take a finger (4). Disconnect from the lever приводной a cable.
5. Turn out three bolts М8 of fastening of a drive of inclusion and two bolts М8 of fastening of a cable. Remove assemblage of a drive with a cable.


Details of installation of a plug of inclusion of a drive of back wheels

1  — the  Ball
2  — the  Spring
3  — the  Plug
4  — a  plug Rod

 


Details of fastening of a lead of the lever of switching

1  — a  switch Axis
2  — the  Screw-clamp
3  — a  lever Lead

 


 PERFORMANCE ORDER

1. With the help a small beard approaching the size beat out from a plug of inclusion of a drive of back wheels (3) spring pin, develop a rod of a plug (4) on 180 and extend it from a plug. Remove a plug.
2. Take a ball and a spring from картера a distributing box.

At extraction of a plug from картера a distributing box put forward on 2 3 mm the safety mechanism of inclusion of transfer of a backing, preliminary having weakened bolts of its fastening. Try not to lose a ball.

3. Turn out seven fixing bolts and remove assemblage of lengthening with details of intermediate transfer of a drive of back wheels.
4. Take the inclusion platen муфты a drive of back wheels from the right wall картера a distributing box.
5. Turn out from картера a distributing box заглушку and take a spring and a ball in diameter of 7.1438 mm.
6. Turn out a fixing bolt and put forward assemblage of the safety mechanism of inclusion of a reverse gear from картера a distributing box so that the mechanism has started to be turned freely.
7. Turn out the screw of fastening of a lead of the lever of switching.
8. Turn out eight fixing bolts and remove картер a distributing box from a transmission, preliminary обстучав its hammer with soft the brisk.


Dismantling of a distributing box

 PERFORMANCE ORDER

1. Take from картера the lever of a gear change with a lead.
2. Remove lubricant knot.
3. Turn out gauges-switches of fires of a backing and a choice of neutral transfer.

The gauge-switch of a choice of neutral transfer can be established not on all models.

4. Turn out two fixing bolts and remove the safety mechanism of inclusion of a reverse gear. Make mechanism dismantling (see above).

Dismantling of lengthening of a box and intermediate transfer of a drive of back wheels

Design of lengthening and intermediate transfer of a drive of back wheels

1  — the  Gauge-switch of activation of a drive of back wheels
2  — the  Lock ring
3  — a  lengthening Shaft
4  — the  Fixing nut with a washer
5  — the  Ball bearing (20х52х15)
6  — the  Conducted gear wheel of intermediate transfer

7  — a  synchronizer Nave
8  — the  Plug of a conducted gear wheel
9  — the  Remote washer
10  — the  Ball bearing (28х68х18)
11  — the  Epiploon


 PERFORMANCE ORDER

1. Turn out the gauge-switch (1) activation of a drive of back wheels.
2. By means of a suitable stripper take a lock ring (2).
3. Having knocked with a hammer with soft brisk on a back end face of a shaft of lengthening liberate it from картера.
4. Include муфту a drive of back wheels and by means of a special key give a nut (4), preliminary having corrected it зачеканенный edge.
5. By means of a stripper remove the ball bearing (5) (20х52х15).
6. Remove the persistent washer, a conducted gear wheel of intermediate transfer and муфту.
7. By means of the special tool remove from a shaft the plug (8) conducted gear wheels of intermediate transfer, a nave of the synchronizer (7), a remote washer (9) and the bearing (10) (28х68х18).

8. Take an epiploon (11).

The removed epiploon is subject to replacement without fail.


Assemblage of lengthening and intermediate transfer of a drive of back wheels

Assemblage is made as it should be the return to an order of dismantle of components.

Assemblage of a distributing box

 PERFORMANCE ORDER

1. Establish a holder of the needle bearing in a nest картера a distributing box.

Try not to damage a stopper inside картера!

2. Screw gauges-switches of fires of a backing and activation of a drive of back wheels and tighten them with demanded effort (18 Nanometers).

Aluminium sealing washers established under gauges are subject to replacement without fail!

3. Plant in an aperture in an end face картера a new epiploon.
4. Establish lubricant knot.
5. Make assemblage of the safety mechanism of inclusion of a reverse gear.
6. Establish assemblage of the safety mechanism in картер a distributing box and fix its two equipped washers bolts, having tightened them with demanded effort (10 Nanometers).
7. Insert the switching lever into a box with the forward party, - track, that the lead has got to a cut of the safety mechanism of inclusion of transfer of a backing. Fill a lever axis in an aperture of a lead and push it inside before occurrence of the end from a back wall картера a distributing box.
8. Grease adjoining details трансмиссионным with oil.
9. Against the stop запрессуйте an epiploon (15х25х2) in the right ledge картера a distributing box.
10. The second epiploon (13х22х6) plant in an aperture of a rod of a plug of switching of a drive of back wheels in a back part картера.
11. Fill the inclusion platen муфты a drive of back wheels from within in an aperture in the right wall картера a distributing box.
12. Make sure of correctness of installation and serviceability of a condition of all provided epiploons.

Installation

 PERFORMANCE ORDER

1. Establish a sealing lining on a back interfaced surface картера a distributing box. Press to a distributing box lengthening assemblage, screw eight fixing bolts and in regular intervals, in a diagonal order tighten them with demanded effort (25 Nanometers).
2. Check up correctness of connection of a lead of the lever of switching with the mechanism of inclusion of a backing. Fix a lead on a lever axis the fixing screw. Tighten the screw with demanded effort (10 Nanometers).
3. Check up correctness of adjustment of neutral position (see above).
4. Pick up a persistent plate of the safety mechanism (see above).
5. Establish a ball ( 7.1438) and a spring, then, having replaced an aluminium washer, screw заглушку and tighten it with demanded effort (10 Nanometers).
6. Establish a lining and lengthening on a distributing box, screw and tighten with demanded effort (34 40 Nanometers) fixing bolts.

At installation of assemblage of lengthening leading and conducted gear wheels of intermediate transfer are necessary for entering into gearing with each other.

7. Establish a plug муфты inclusions of a drive of back wheels. Track, that the plug has got to a reciprocal flute муфты and achieve combination of cut of a plug with the switching platen.

Before installation of last it is necessary to grease nylon tips of a plug slightly трансмиссионным with oil.


Installation of a spring and clamp ball

1  — the  Ball
2  — the  Spring
3  — a  plug Rod

 


 PERFORMANCE ORDER

1. Plant a spring (2) and a ball (1) ( 6.35 mm) a clamp in картер.
2. Fill a rod (3) plugs in an aperture in the middle of the top part of assemblage lengthening.

Rod establish the oblique party forward.

3. Pass a rod through an aperture in a plug, simultaneously keeping a clamp ball in the nest.
4. Achieve combination of apertures under pin installation in a plug and a rod. Fasten details a pin (5х25).

Track, that both ends of a spring pin slightly acted from apertures in a plug. Not to damage an epiploon, grease a rod surface трансмиссионным with oil.

5. Achieve combination of a ball of a clamp with a cut on a rod surface, - try not to drop a ball.
6. Establish Assemblage of a drive of inclusion муфты in gathering with приводным a cable. The cable tip incorporates to the lever by means of a finger and a clamp. Drive fastening on a left-hand side картера transmissions is carried out by means of bolts М8. Two more equipped washers bolts М8 fix a cable plate. The demanded effort of a tightening of bolts makes 16 Nanometers.
7. Put on the lever the inclusion platen муфты a drive of back wheels and fix it by means of a spring pin.
7. Connect a hose to a tube on a drive, then by means of the manual vacuum pump create in a drive depression for which account the cable should be involved as much as possible in a cover.
8. Continuing to support depression, turn coupling муфту, to the full having truncated a cable. Then release муфту, having developed it back on 180 , and tighten with demanded effort (5 Nanometers) two lock nuts.
9. Include a drive of back wheels and make sure of smoothness of operation муфты.
10. Establish a cover картера a distributing box. Screw and tighten with demanded effort (15 18 Nanometers) fixing bolts.
11. Restore initial connection of electroconducting.