BACK-UP LIGHT SWITCH Subaru Legacy BM/BR рестайлинг

BACK-UP LIGHT SWITCH

Check the back-up light switch. Refer to INSPECTION .

Scheme 208

1. Turn the ignition switch to OFF.
2. Disconnect the connector of neutral position switch.
3. Measure the resistance between neutral position switch terminals. Gear shift position Terminal No. Specified resistance Neutral position 1 and 2 Less than 1 ohms Other positions 1 Mohms or more
4. Replace faulty parts.

Scheme 209

1. Clean oil, grease, dirt and dust from the transmission.
2. When gear oil remains in the transmission, using the TORX® bit T70, remove the drain plug, and drain the transmission gear oil completely.
3. Tighten the drain plug using TORX® bit T70. NOTE: Use a new gasket. Tightening torque: 44 N.m (4.5 kgf-m, 32.5 ft-lb) (Aluminum gasket silver) 70 N.m (7.1 kgf-m, 51.6 ft-lb) (Copper gasket brown) 70 N.m (7.1 kgf-m, 51.6 ft-lb) (Metal gasket black)
4. Attach the transmission to the ST. ST 499937100 TRANSMISSION STAND
5. Apply oil to rotating parts before assembly.
6. All disassembled parts, if to be reused, should be reinstalled in the original positions and directions.
7. Gaskets, lock washers and lock nuts must be replaced with new ones.
8. Apply liquid gasket to the specified areas to prevent leakage.

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1. Remove the manual transmission assembly from the vehicle. Refer to «REMOVAL»(ref-565169-S30911287192013071000000) .
2. Remove the back-up light switch and the neutral position switch. Refer to «REMOVAL»(ref-565169-S11680300332013071000000) .
3. Remove the transfer case together with the extension case assembly. Remove the transmission cover. Set and hold the selector lever COMPL to the 1st-2nd side, and remove the transfer case and extension case assembly as a unit.
4. Use the ST to push out the spring pin and remove the shift lever COMPL from shifter arm No. 2. ST 398791700 SPRING PIN REMOVER 2
5. Remove the extension case assembly.
6. Remove the transfer driven gear and center differential as a unit.

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1. Clean the mating surface of the extension case assembly and transfer case and the mating surface of transfer case and transmission cover.
2. Install the center differential and transfer driven gear into the transfer case.
3. Remove the bearing outer race from the extension case.
4. Install the bearing outer race to transfer driven gear.
5. While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns.
6. Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.
7. Measure depth "X" of bearing insertion part of the extension case. NOTE: Measure with bearing outer race and thrust washer removed.
8. Calculate the thrust washer thickness "t" using the following calculation. t = X - W + (0.15 - 0.2 mm (0.006 - 0.008 in))
9. Select the washer with the nearest value in the following table. NOTE: Be sure that it is always within the preload. Preload of the taper roller bearing (amount of standard protrusion): 0.15 - 0.20 mm (0.006 - 0.008 in) Thrust washer (50 x 61 x t) Part No. Thickness mm (in) 803050060 0.50 (0.0197) 803050061 0.55 (0.0217) 803050062 0.60 (0.0236) 803050063 0.65 (0.0256) 803050064 0.70 (0.0276) 803050065 0.75 (0.0295) 803050066 0.80 (0.0315) 803050067 0.85 (0.0335) 803050068 0.90 (0.0354) 803050069 0.95 (0.0374) 803050070 1.00 (0.0394) 803050071 1.05 (0.0413) 803050072 1.10 (0.0433) 803050073 1.15 (0.0453) 803050074 1.20 (0.0472) 803050075 1.25 (0.0492) 803050076 1.30 (0.0512) 803050077 1.35 (0.0531) 803050078 1.40 (0.0551) 803050079 1.45 (0.0571)
10. Install the selected thrust washer and bearing outer race to the extension case.
11. Measure the depth "S" between transfer case and center differential. ST 398643600 GAUGE
12. Measure the height "T" between the extension case and transfer drive gear. ST 398643600 GAUGE
13. Calculate the thrust washer thickness "U" using the following calculation. U = S + T - 30 mm (1.18 in) - (0.15 - 0.35 mm (0.00590 - 0.0138 in)) S: Depth between transfer case and center differential T: Depth between the extension case and transfer gear 30 mm (1.18 in): Thickness of ST 0.15 - 0.35 mm (0.0059 - 0.0138 in): Clearance
14. Select a suitable thrust washer in the following table. Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 in) Thrust washer Part No. Thickness mm (in) 803036050 0.9 (0.035) 803036054 1.0 (0.039) 803036051 1.1 (0.043) 803036055 1.2 (0.047) 803036052 1.3 (0.051) 803036056 1.4 (0.055) 803036053 1.5 (0.059) 803036057 1.6 (0.063) 803036058 1.7 (0.067) 803036080 1.8 (0.071) 803036081 1.9 (0.075)
15. Fit the thrust washer onto the center differential.
16. Apply liquid gasket seamlessly to the mating surface of transfer case. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
17. Install the extension case assembly to the transfer case. Tightening torque: 40 N.m (4.1 kgf-m, 29.5 ft-lb)
18. Temporarily install the gasket to the transmission case side. NOTE: Use a new gasket.
19. Install the extension case assembly along with the transfer case to the transmission case. While moving the HANDLE to align the spline position, press in the transfer case assembly until the knock pin comes slightly out of transfer case. ST 18631AA000 HANDLE Set and hold the selector lever to the 1st-2nd side, and install the transfer case assembly so that the shifter arm edge and fork rod does not contact.
20. Temporarily tighten the transfer case assembly.
21. Install the shift lever COMPL to the shifter arm No. 2, then insert the remover or similar tool instead of spring pin.
22. Operate the selector arm and remover to confirm the correct shifting into each gear is possible.
23. Tighten the transfer case assembly to the specified torque. Tightening torque: 24.5 N.m (2.5 kgf-m, 18.1 ft-lb)
24. Install the shift lever COMPL to the shifter arm No. 2, then fix it using a spring pin. NOTE: Use new spring pin.
25. Apply liquid gasket seamlessly to the mating surface of transmission cover. Liquid gasket: THREE BOND 1215 (Part No. 004403007) or equivalent
26. Install the transmission cover to transfer case. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

Scheme 228

1. Remove the interlock plate. NOTE: Do not remove the precoat bolt (B) if the parts are assembled as a transmission assembly. Do not reuse the precoat bolt and gasket once the interlock plate is removed.
2. Remove the shift link assembly. Refer to «REMOVAL»(ref-565169-S28474402092013071000000) .