Test Methods — Part 1 Subaru Forester SF рестайлинг

Test Methods

1. Fully apply the parking brake.
2. Start the engine. Check engine speed is in idling speed (A/C OFF).
3. Shift the shift lever from "N" to "D" range. Using a stop watch, measure the time it takes from shifting the lever until the shock is felt. Time lag: Less than 1.2 seconds
4. In same manner, measure the time lag for "N" --> "R". Time lag: Less than 1.5 seconds

Check transfer clutch pressure in accordance with the following chart in the same manner as with line pressure.

ST 498897700 OIL PRESSURE ADAPTER SET

ST 498575400 OIL PRESSURE GAUGE ASSEMBLY

AWD mode: "D" range

FWD mode: "P" range, engine speed 2,000 rpm

Identifying Pressure Gauge Test Plug For Transfer Clutch At Transmission. Scheme 78

Make sure that each component is free of harmful gouges, cuts, or dust.

Scheme 79

1. Press-fit the reduction drive gear to the shaft.
2. Press-fit the ball bearing to the reduction drive gear.
3. Attach two seal rings. NOTE: To make subsequent assembly easier, apply vaseline to the grooves of the shaft and to the exterior of the seal ring. (Scheme 79): Installing Seal Rings

Scheme 80

Scheme 81

1. Remove snap ring from reduction driven gear. (Scheme 80): Removing Snap Ring From Reduction Driven Gear
2. Using ST, remove ball bearing from reduction driven gear. ST 498077600 REMOVER (Scheme 81): Removing Ball Bearing From Reduction Driven Gear

Check ball bearing and gear for dents or damage.

Scheme 82

Scheme 83

1. Using a press, install ball bearing to reduction driven gear. (Scheme 82): Installing Ball Bearing To Reduction Driven Gear
2. Install snap ring to reduction driven gear. (Scheme 83): Installing Snap Ring To Reduction Driven Gear

Make sure that each component is free of harmful gouges, cuts, or dust.

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

1. Install accumulator pistons, valve springs and steel balls to upper valve body. CAUTION: Insert steel balls in their proper positions. (Scheme 84): Installing Accumulator Pistons & Related Components
2. Install support plate and upper separate plate to middle valve body. CAUTION: Align the hole in support plate with the hole in separate plate. Tightening torque: 8+/-1 N.m (0.8+/-0.1 kg-m, 5.8+/-0.7 ft-lb) (Scheme 85): Installing Support Plate & Related Components
3. Install the steel balls to middle valve body. CAUTION: Insert steel the balls in their proper positions. (Scheme 86): Installing Steel Balls To Middle Valve Body
4. Install three filters to lower valve body. CAUTION: Pay attention to the location of filters. (Scheme 87): Installing Filters (Strainers) To Lower Valve Body
5. Install lower separate plate to lower valve body. (Scheme 88): Installing Lower Separate Plate To Lower Valve Body
6. Temporarily assemble valve body. CAUTION: Be careful not to drop the middle valve body and upper body interior steel ball, or the lower body filter. (Scheme 89): Identifying Temporarily Assembled Valve Body
7. Tighten bolts. Tightening torque: 8+/-1 N.m (0.8+/-0.1 kg-m, 5.8+/-0.7 ft-lb) (Scheme 90): Identifying Valve Body Bolt Types
8. Install the sensor, solenoids and duty solenoids. Tightening torque: T: 8+/-1 N.m (0.8+/-0.1 kg-m, 5.8+/-0.7 ft-lb) (Scheme 91): Installing Sensor, Solenoids & Duty Solenoids
9. Install oil strainer to lower valve body. Tightening torque: 8+/-1 N.m (0.8+/-0.1 kg-m, 5.8+/-0.7 ft-lb)

Scheme 92

Scheme 93

Scheme 94

Scheme 95

1. Remove the oil seal retainer. Also remove the O-ring and oil seal (air breather). (Scheme 92): Removing Oil Seal Retainer
2. Remove O-rings from oil pump housing. CAUTION: Be careful not to damage O-ring.
3. Remove the four seal rings. CAUTION: Be careful not to damage seal ring. (Scheme 93): Removing Four Seal Rings
4. Remove the oil pump cover. NOTE: Lightly tap the end of the stator shaft to remove the cover. (Scheme 94): Removing Oil Pump Cover
5. Remove the inner and outer rotor. (Scheme 95): Removing Inner & Outer Rotor

Scheme 96

Scheme 97

Scheme 98

1. Check seal ring and O-ring oil seal for breaks or damage.
2. Check other parts for dents or abnormalities.
3. Selection of oil pump rotor assembly Tip clearance Install inner rotor and outer rotor to oil pump. With rotor gears facing each other, measure crest-to-crest clearance. Tip clearance: 0.02 - 0.15 mm (0.0008 - 0.0059 in) (Scheme 96): Measuring Crest To Crest Clearance Side clearance Set a depth gauge to oil pump housing, then measure oil pump housing-to-rotor clearances. Side clearance: 0.02 - 0.04 mm (0.0008 - 0.0016 in) (Scheme 97): Measuring Oil Pump Housing To Rotor Clearances If depth and/or side clearances are outside specifications, replace rotor assembly. (Scheme 98): Oil Pump Rotor Assembly Specifications

Scheme 99

Scheme 100

Scheme 101

1. Install oil pump rotor assembly to oil pump housing. (Scheme 99): Installing Oil Pump Rotor Assembly To Oil Pump Housing
2. Install the oil pump cover. Tightening torque: 25+/-2 N.m (2.5+/-0.2 kg-m, 18.1+/-1.4 ft-lb) NOTE: Align both pivots with the pivot holes of the cover, and install the cover being careful not to apply undue force to the pivots. After assembling, turn the oil pump shaft to check for smooth rotation of the rotor. (Scheme 100): Installing Oil Pump Cover Install the oil seal retainer and seal rings. After adjusting the drive pinion backlash and tooth contact. (Scheme 101): Install Oil Seal Retainer & Seal Rings

Scheme 102

Scheme 103

Scheme 104

1. Straighten the staked portion of the lock nut, and remove the lock nut while locking the rear spline portion of the shaft with ST1 and ST2. Then pull off the drive pinion collar. ST1 498937110 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER (Scheme 102): Removing Drive Pinion Collar
2. Remove the O-ring.
3. Using a press, separate the rear roller bearing and outer race from the shaft. (Scheme 103): Removing Rear Roller Bearing & Outer Race From The Shaft
4. Using a press and ST, separate the front roller bearing from the shaft. ST 498517000 REPLACER (Scheme 104): Separating Front Roller Bearing From Shaft

Make sure that all component parts are free of harmful cuts, gouges, and other faults.

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

1. Measure dimension "A" of the drive pinion shaft. ST 398643600 GAUGE (Scheme 105): Measuring Dimension "A" Of Drive Pinion Shaft
2. Using a press, force-fit the roller bearing in position. CAUTION: Do not change the relative positions of the outer race and bearing cone. (Scheme 106): Installing Roller Bearing Into Position
3. After fitting the O-ring to the shaft, attach the drive pinion collar to the shaft. CAUTION: Be careful not to damage the O-ring.
4. Tighten the lock washer and lock nut with ST1, ST2 and ST3. ST1 498937110 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER Actual tightening torque: 116+/-5 N.m (11.8+/-0.5 kg-m, 85.3+/-3.6 ft-lb) NOTE: Pay attention to the orientation of lock washer. Tightening torque using torque wrench is determined by the following equation. T 1 = L/ L + 72.2 X T T: Actual tightening torque Install ST2 to torque wrench as straight as possible. (Scheme 107): Installing (ST2) To Torque Wrench As Straight As Possible
5. Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If out of the allowable range, replace the roller bearing. Starting torque: 0.3 - 2.0 N.m (0.03 - 0.2 kg-m, 0.2 - 1.4 ft-lb) (Scheme 108): Measuring Starting Torque Of Bearing
6. Stake the lock nut securely at two places.
7. Measure dimension "B" of the drive pinion shaft. ST 398643600 GAUGE (Scheme 109): Measure Dimension "B" Of Drive Pinion Shaft
8. Determine the thickness "t" (mm) of the drive pinion shim. NOTE: The number of shims must be three or less. t = 6.5+/-0.0625 - (B - A) (Scheme 110): Determining Thickness "t" (mm) Of Drive Pinion Shim

Identifying High Clutch & Reverse Clutch Components. Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

1. Remove the snap ring, and take out the retaining plate, drive plates, driven plates. (Scheme 112): Removing Snap Ring
2. Remove snap ring, and take out the retaining plate, drive plates and driven plates. (Scheme 113): Removing Snap Ring
3. Using ST1 and ST2, remove snap ring. ST1 398673600 COMPRESSOR ST2 498627100 SEAT (Scheme 114): Removing Snap Ring Using (ST1) & (ST2)
4. Take out clutch cover, spring retainer, high clutch piston and reverse clutch piston. (Scheme 115): Removing Clutch Cover
5. Remove seal rings and lip seal from high clutch piston and reverse clutch piston. (Scheme 116): Removing Seal Rings & Lip Seal

1. Drive plate facing for wear and damage
2. Snap ring for wear, return spring for breakage or setting, and spring retainer for deformation
3. Lip seal and lathe cut seal ring for damage
4. Piston check ball for operation

Identifying High Clutch & Reverse Clutch Components. Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

1. Install seal rings and lip seal to high clutch piston and reverse clutch piston.
2. Install high clutch piston to reverse clutch piston. (Scheme 118): Installing Seal Rings & Lip Seal
3. Install reverse clutch to high clutch drum. NOTE: Align the groove on the reverse clutch piston with the groove on the high clutch drum during installation. (Scheme 119): Installing Reverse Clutch To High Clutch Drum
4. Install spring retainer to high clutch piston. (Scheme 120): Installing Spring Retainer To High Clutch Piston
5. Install ST to high clutch piston. ST 498437000 HIGH CLUTCH PISTON GAUGE (Scheme 121): Installing High Clutch Piston Using (ST)
6. Install cover to high clutch piston. CAUTION: Be careful not to fold over the high clutch piston seal during installation.
7. Using ST1 and ST2, install snap ring. NOTE: After installing snap ring, remove STs. ST1 398673600 COMPRESSOR ST2 498627100 SEAT ST3 498437000 HIGH CLUTCH PISTON GAUGE (Scheme 122): Installing Snap Ring Using (ST1) & (ST2)
8. Install driven plate, drive plate and retaining plate to high clutch drum. NOTE: Install a thicker driven plate on the piston side. (Scheme 123): Installing Driven Plate & Related Components
9. Install snap ring to high clutch drum.
10. Apply compressed air intermittently to check for operation. (Scheme 124): Checking Assembled Parts For Operation
11. Measure the clearance between the retaining plate and snap ring. CAUTION: Do not press down retaining plate during clearance measurements. Standard value: 0.8 - 1.1 mm (0.031 - 0.043 in Allowable limit: 1.5 mm (0.059 in) (Scheme 125): Measuring Clearance Between Retaining Plate & Snap Ring
12. If specified tolerance limits are exceeded, select a suitable high clutch retaining plate. (Scheme 126): High Clutch Retaining Plate Chart
13. Install driven plate, drive plate, retaining plate and snap ring. (Scheme 127): Install Driven Plate, Drive Plate, Retaining Plate & Snap Ring
14. Apply compressed air intermittently to check for operation. (Scheme 128): Checking Assembled Parts For Smooth Operation
15. Measure the clearance between the retaining plate and snap ring. CAUTION: Do not press down retaining plate during clearance measurements. Standard value: 0.5 - 0.8 mm (0.020 - 0.031 in) Allowable limit: 1.2 mm (0.047 in) (Scheme 129): Measuring Clearance Between Retaining Plate & Snap Ring
16. If specified tolerance limits are exceeded, select a suitable reverse clutch retaining plate. (Scheme 130): Reverse Clutch Retaining Plate Chart

Identifying Low Clutch Drum & Planetary Gear Components. Scheme 131

Scheme 132