Subaru Forester

1997-2005 of release

Repair and operation of the car

Dismantling and assembly of the transfer case, service of components

Dismantling of the transfer case

Extraction of internal components of the transfer case

1  —  the Case of the transfer case 2  —  Interaxal differential and a shaft of the conducted gear wheel of intermediate transfer of the drive of back wheels 3  —  the Adjusting washer 4  —  the Adjusting washer 5  —  Assembly of lengthening of RKPP

PERFORMANCE ORDER

1. Separate assembly of lengthening of RKPP from a box case. 2. Take the conducted shaft assembled with a gear wheel of intermediate transfer of the drive of back wheels and interaxal differential. 3. Remove an adjusting washer of the conducted shaft of intermediate transfer of the 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 turning on of the reverse gear

1  —  the Transfer case 2  —  the Screw of fastening of the lever of switching to a rod 3  —  the Sleeve of the safety mechanism 4  —  the cam Roller 5  —  the Cover of a case of the transfer case

The scheme of an arrangement on a case of the transfer case of sensors switches, the safety mechanism of turning on of the reverse gear and a lead of the lever of switching

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

PERFORMANCE ORDER

1. Release the lever of switching and remove its lead. Before removal of the lever disconnect the sensor switch of inclusion of neutral transfer. 2. Turn out a cap and take a spring and a ball of the safety mechanism of turning on of the reverse gear.

Design of safety fur of turning on of the reverse gear

1  —  the Sealing ring 2  —  the Sleeve 3  —  the cam Roller (is selected at adjustment) 4  —  the Returnable spring of the roller 5  —  the Cam 6  —  Pruzhina of a cam 7  —  the Persistent plate (is selected at adjustment) 8  —  the Lock ring

PERFORMANCE ORDER

1. Remove the safety mechanism. Having hooked the screw-driver, take the lock ring established from the face party of a sleeve. Disassemble the safety mechanism. The deformed or weakened lock ring is subject to replacement! 2. Turn out the sensor switch of fires of a backing. 3. Remove lubricant knot.

Dismantling of lengthening of RKPP

PERFORMANCE ORDER

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

The bearing should be taken from a lengthening case only if it needs replacement.

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

Assembly of lengthening of RKPP

PERFORMANCE ORDER

1. Install the ball bearing in a case of lengthening and pick up a lock ring so that the gap between it and an external holder of the bearing made 0 ÷ 0.15 mm. Lock rings 1.78, 1.90 and 2.02 mm thick (Ø of 72 mm) are issued. 2. Press a shaft of the leading gear wheel of intermediate transfer to the bearing. 3. Put a lock ring on a shaft. Measure gap size between a ring and an internal holder of the bearing. The nominal rate makes 0 ÷ 0.15 mm. Lock rings 1.53, 1.65 and 1.77 mm thick (Ø of 30 mm) are issued. 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 gear shifting. 6. Put a new epiploon in the lengthening case.

Assembly of the transfer case

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

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

PERFORMANCE ORDER

1. Assembly is made as it should be the return to an order of dismantle of components. Special attention should be paid to the listed below moments. 2. At assembly of the safety mechanism of inclusion of transfer of a backing track that the unbent end of a spring got to a reciprocal cut in a cam. Install the cam roller, a cam, a returnable spring and a spring of a cam 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 seemed in a cut of a plate and, holding a cam in this situation, fill a persistent plate in a sleeve, then record components by means of a lock ring. Put in an external flute on a sleeve surface a new sealing ring (34.5х1.5). 3. Make sure of correctness of assembly of the safety mechanism. Check that the cut of the roller of a cam remained it is combined with a cut in a sleeve. Manually check smoothness of the course of a cam at its turning, - if at an otpuskaniye the cam does not come back to a starting position, replace its spring. Shift assembly of a cam with the roller towards a persistent plate, then release, - if at an otpuskaniye the cam does not come back to a starting position, replace its spring. If the roller does not come back, check a condition of an internal surface of a sleeve, - in the absence of defects replace a returnable spring. Pick up the rollers of a cam and a persistent plate suitable by the sizes. 4. Install the gear shifting lever in the transfer case from 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 opening, continue to push it until the end of an axis does not seem from a back wall of the transfer case. 5. Oil gearbox gear shifting mechanism components. 6. Make sure of correctness of installation and serviceability of a condition of all epiploons.

Connection of the transfer case with lengthening of RKPP

Assembly of lengthening with the transfer case

1 —  Interaxal differential and a shaft of the leading gear wheel of intermediate transfer 2  —  the Adjusting washer (is selected at adjustment) 3  —  the Adjusting washer (is selected at adjustment) 4  —  the Case of the transfer case 5  —  lengthening of the transfer case

Measurement of size of a vystupaniye of differential over the plane of a case of the transfer case

1  —  Interaxal differential 2  —  the Case

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

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

PERFORMANCE ORDER

1. Establish interaxal differential and the leading gear wheel of intermediate transfer with shaft to a case of a distributing box / 2. Measure differential vystupaniye size A over the case plane. 3. Measure depth In landings of a shaft of the leading gear wheel of an intermediate gear wheel in lengthening of the transfer case. 4. Calculate gap size With on a formula: With = In - And + 0.24 (mm), where 0.24 mm - laying thickness.

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

Gap size between an adjusting washer of differential and the persistent bearing makes 0.35 ÷ of 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 the conducted gear wheel of intermediate transfer over the interfaced surface of a case of the transfer case

1  —  the Shaft of the conducted gear wheel 2  —  the Bearing 3  —  the Case of the transfer case

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

1  —  Lengthening of the transfer case

PERFORMANCE ORDER

1. Establish a washer on interaxal differential. 2. Now pick up an adjusting washer of the bearing of the conducted shaft of intermediate transfer of the drive of back wheels: measure height W landings of the bearing of a shaft of an intermediate gear wheel over the interfaced surface of a case of the transfer case. 3. Measure size X. 4. Count Y gap size on a formula: Y = X - W + 0.24 (mm), where 0.24 mm - laying thickness.

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

Gap of Y, mm	Adjusting washer of interaxal differential
	detail No.	Thickness, mm
1.60 ÷ 1.74	803052021	0.50
1.75÷ 1.89	803052022	0.75
1.90 ÷ 2.04	803052023	1.00

Gap size between an adjusting washer and the bearing makes 0.05 ÷ of 0.30 mm.

PERFORMANCE ORDER

1. Establish a washer on a shaft. 2. Establish assembly of lengthening on a case of the transfer case.

Installation and adjustment

PERFORMANCE ORDER

1. Install assembly of the transfer case with lengthening on the transmission. 2. Put on a lead of the lever of switching to the lever and fix it by the fixing screw. Track that the lead got to a cut of the safety mechanism of turning on of the reverse gear! 3. Include the 3rd transfer. The lever of switching has to move rather freely towards inclusion of 1/2 transfers, however, thanks to the effort developed by a returnable spring show noticeable resistance in attempt of turning on of the reverse gear (against the stop to the limiter). 4. Adjust effort of resistance of the lever to turning on of the reverse gear so that only not much more surpassed resistance at inclusion of 1/2 transfers. Adjustment is made by a selection of the adjusting laying established between a case of the transfer case and a sleeve of the safety mechanism, - turn out bolts of fastening of the safety mechanism.

Try not to damage a sealing ring at selection of laying! Laying of two standard sizes is issued: No. 32190AA000, 0.15 mm thick and No. 32190AA010, 0.30 mm thick.

During removal of laying neutral position of the switch approaches a point of inclusion of a backing, at addition - a point of inclusion of 1/2 transfers.

If it is not possible to achieve the required result by laying selection, replace the cam roller in the safety mechanism. At an end face of the roller there is an identification marking by means of which it is easy to define its dimensional characteristics:

Cam roller

detail No.	32188AA020
Tag	And
Note	Neutral position of the switch comes nearer to a point of inclusion of the 1st transfer
detail No.	32188AA002
Tag	In / is absent
detail No.	32188AA030
Tag	With
Note	Neutral position of the switch approaches a point of turning on of the reverse gear

PERFORMANCE ORDER

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

Persistent plate
detaloa No.	Marking	Corner	Notes
32189AA020	0	34 °	The switch is displaced closer to the provision of inclusion of the 5th transfer
32189AA020	1	34 °	The switch is displaced closer to the provision of inclusion of the 5th transfer
32189AA020	2	34 °	Standard
32189AA030	3	37 °	The switch is displaced closer to the provision of turning on of the reverse gear
32189AA040	4	40 °	The switch is displaced closer to the provision of turning on of the reverse gear

Removal, service and installation of the transfer case and lengthening of RKPP (model with the switched-off all-wheel drive)

Removal

Design of the transfer case and lengthening of RKPP (model with the switched-off drive of back wheels)

1  —  the Cover of a case of the transfer case 2  —  Sealing laying 3  —  the Spring pin 4  —  the Fork of turning on of the coupling of the drive of back wheels 5  —  Lubricant knot 6  —  the Ball 7  —  Pruzhina 8  —  the Roller of turning on of the coupling of the drive of back wheels 9  —  the External executive lever of turning on of the drive 10  —  the Finger 11  —  the Spring pin 12  —  the Clamp 13  —  the Epiploon 14  —  Sealing laying 15  —  the Case of the transfer case 16  —  the Sensor switch of fires of a backing 17  —  the Sensor switch of the choice of neutral transfer 18  —  the Epiploon 19  —  the Holder of the needle bearing 20  —  the Rod of a fork of turning on of the drive of back wheels

21  —  the Epiploon 22  —  a lengthening Shaft 23  —  Sealing laying 24  —  Lengthening 25  —  Sealing laying 26  —  the Sensor switch of the four-wheel drive 27  —  the Epiploon 28  —  the Boot 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  —  a coupling Nave 36  —  the Coupling of turning on of the back drive 37  —  the Remote washer 38  —  the Lock ring 39  —  the Bearing

Details of connection of the drive of inclusion

1  —  the Roller of turning on of the coupling of the drive of back wheels 2  —  the Spring pin (5.2 x 8) 3  —  a cable Tip 4  —  the Finger 5  —  the Clamp 6  —  the External executive lever

PERFORMANCE ORDER

1. The design of assembly of the transfer case and lengthening of RKPP is presented on an accompanying illustration. 2. Disconnect all electrical wiring brought to RKPP. 3. Vypressuyte the spring pin (2) connecting the external executive lever (9) to the roller of the coupling of the drive of back wheels also remove the lever. 4. Remove a clamp (5) and take a finger (4). Disconnect a driving cable from the lever. 5. Turn out three bolts of M8 of fastening of the drive of inclusion and two bolts of M8 of fastening of a cable. Remove assembly of the drive with a cable.

Details of installation of a fork of turning on of the drive of back wheels

1  —  the Ball 2  —  Pruzhina 3  —  the Fork 4  —  a fork 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 suitable the size beat out a spring pin from a fork of turning on of the drive of back wheels (3), develop a rod of a fork (4) on 180 ° and extend it from a fork. Remove a fork. 2. Take a ball and a spring from a case of the transfer case. At extraction of a fork from a case of the transfer case nominate the safety mechanism of inclusion of transfer of a backing to 2 ÷ 3 mm, previously having weakened bolts of its fastening. Try not to lose a ball. 3. Turn out seven fixing bolts and remove assembly of lengthening with details of intermediate transfer of the drive of back wheels. 4. Take the roller of turning on of the coupling of the drive of back wheels from the right wall of a case of the transfer case. 5. Turn out a cap from a case of the transfer case and take a spring and a ball with a diameter of 7.1438 mm. 6. Turn out fixing a bolt and put forward assembly of the safety mechanism of turning on of the reverse gear from a case of the transfer case so that the mechanism began 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 a case of the transfer case from the transmission, previously having tapped it the hammer with soft brisk.

Dismantling of the transfer case

PERFORMANCE ORDER

1. Take from a case the gear shifting lever with a lead. 2. Remove lubricant knot. 3. Turn out sensors switches of fires of a backing and the choice of neutral transfer. The sensor switch of the choice of neutral transfer can be installed not on all models. 4. Turn out two fixing bolts and remove the safety mechanism of turning on of the reverse gear. Make dismantling of the mechanism (see above).

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

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

1  —  the Sensor switch of activation of the 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 the conducted gear wheel 9  —  the Remote washer 10  —  the Ball bearing (28х68х18) 11  —  the Epiploon

PERFORMANCE ORDER

1. Turn out the sensor switch (1) of activation of the drive of back wheels. 2. By means of a suitable stripper take a lock ring (2). 3. Having knocked with the hammer with soft brisk on a back end face of a shaft of lengthening release it from a case. 4. Turn on the coupling of the drive of back wheels and by means of a special key give a nut (4), previously having corrected its fullered edge. 5. By means of a stripper remove the ball bearing (5) (20x52x15). 6. Remove a persistent washer, the conducted gear wheel of intermediate transfer and the coupling. 7. By means of the special tool remove the plug (8) of the conducted gear wheel of intermediate transfer, a nave of the synchronizer (7), a remote washer (9) and the bearing (10) (28x68x18) from a shaft. 8. Take an epiploon (11).

The removed epiploon is subject to replacement without fail.

Assembly of lengthening and intermediate transfer of the drive of back wheels

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

Assembly of the transfer case

PERFORMANCE ORDER

1. Establish a holder of the needle bearing in a nest of a case of the transfer case. Try not to damage a stopper in a case! 2. Screw sensors switches of fires of a backing and activation of the drive of back wheels and tighten them with the required effort (18 Nanometers). The aluminum sealing washers established under sensors are subject to replacement without fail! 3. Put in an opening in a case end face a new epiploon. 4. Establish lubricant knot. 5. Make assembly of the safety mechanism of turning on of the reverse gear. 6. Establish assembly of the safety mechanism in a case of the transfer case and fix it by two bolts equipped with washers, having tightened them with the required effort (10 Nanometers). 7. Insert the switching lever into a box from the forward party, - track that the lead got to a cut of the safety mechanism of inclusion of transfer of a backing. Fill a lever axis in an opening of a lead and push it inside before emergence of the end from a back wall of a case of the transfer case. 8. Oil the adjoining details gearbox. 9. Against the stop press an epiploon (15х25х2) in the right ledge of a case of the transfer case. 10. Put the second epiploon (13х22х6) in an opening of a rod of a fork of switching of the drive of back wheels in a back part of a case. 11. Fill the roller of turning on of the coupling of the drive of back wheels from within in an opening in the right wall of a case of the transfer case. 12. Make sure of correctness of installation and serviceability of a condition of all provided epiploons.

Installation

PERFORMANCE ORDER

1. Establish sealing laying on the back interfaced surface of a case of the transfer case. Press lengthening assembly to the transfer case, screw eight fixing bolts and evenly, in a diagonal order tighten them with the required effort (25 Nanometers). 2. Check 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 by the fixing screw. Tighten the screw with the required effort (10 Nanometers). 3. Check correctness of adjustment of neutral situation (see above). 4. Pick up a persistent plate of the safety mechanism (see above). 5. Establish a ball (Ø 7.1438) and a spring, then, having replaced an aluminum washer, screw a cap and tighten it with the required effort (10 Nanometers). 6. Install laying and lengthening on the transfer case, screw and tighten fixing bolts with the required effort (34 ÷ 40 Nanometers). At lengthening assembly installation the conducting and conducted gear wheels of intermediate transfer need to be entered into gearing with each other. 7. Establish a fork of the coupling of turning on of the drive of back wheels. Track that the fork got to a reciprocal flute of the coupling and achieve combination of a cut of a fork with the switching roller.

Nylon tips of a fork before installation of the last should be oiled slightly gearbox.

Installation of a spring and ball of a clamp

1  —  the Ball 2  —  Pruzhina 3  —  a fork Rod

PERFORMANCE ORDER

1. Put a spring (2) and a ball (1) (Ø of 6.35 mm) of a clamp in a case. 2. Fill a rod (3) forks in an opening in the middle of the top part of assembly lengthening. Establish a rod by the slanted party forward. 3. Pass a rod through an opening in a fork, at the same time holding a clamp ball in the nest. 4. Achieve combination of openings under installation of a pin in a fork and a rod. Fasten details with a pin (5х25). Track that both ends of a spring pin slightly acted from openings in a fork. Not to damage an epiploon, oil a rod surface gearbox. 5. Achieve combination of a ball of a clamp with a cut on a rod surface, - try not to drop a ball. 6. Establish Assembly of the drive of turning on of the coupling assembled with a driving cable. The tip of a cable connects to the lever by means of a finger and a clamp. Fastening of the drive on the left side of a case of the transmission is carried out by means of M8 bolts. fix by two more bolts of M8 equipped with washers a cable plate. The required effort of tightening of bolts makes 16 Nanometers. 7. Put on the lever the roller of turning on of the coupling of the drive of back wheels and fix it by means of a spring pin. 7. Connect a hose to a tube on the drive, then by means of the manual vacuum pump create in the drive depression due to which the cable has to be involved as much as possible in a cover. 8. Continuing to support depression, turn the coupling coupling, having to the full truncated a cable. Then release the coupling, having deployed it back on 180 °, and tighten two lock nuts with the required effort (5 Nanometers). 9. Turn on the drive of back wheels and make sure of smoothness of operation of the coupling. 10. Establish a cover of a case of the transfer case. Screw and tighten fixing bolts with the required effort (15 ÷ 18 Nanometers). 11. Restore initial connection of an electrical wiring.