Overhauling a gear set in a Subaru Legacy can be a complex task, especially if you have limited mechanical experience. View and download the manual with one click here……
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However, I’ll break it down into simpler steps. Please remember that this is a general overview, and you should consult the vehicle’s service manual for specific details and torque specifications. If at any point you feel overwhelmed, it’s a good idea to seek help from a professional mechanic.
### Tools and Materials Needed:
1. **Basic Tools:**
– Socket set
– Wrenches
– Screwdrivers
– Pliers
– Torque wrench
– Hammer (soft face)
2. **Specialty Tools:**
– Gear puller
– transmission jack or support
– Dial indicator (for measuring gear backlash)
– Micrometer or caliper (for measuring parts)
– Service manual for specifications and procedures
3. **Replacement Parts:**
– Gaskets and seals
– Bearings
– Gears (if damaged)
– Gear oil
### Steps to Overhaul Gear Set:
#### 1. **Preparation:**
– **Safety First:** Make sure to wear safety glasses, gloves, and work in a well-ventilated area.
– **Disconnect the Battery:** Always disconnect the negative terminal of the battery to avoid electrical issues.
#### 2. **Remove the Transmission:**
– **Lift the Vehicle:** Use a jack to lift the car and secure it on jack stands.
– **Drain the Fluid:** Place a pan under the transmission and remove the drain plug to let the fluid out.
– **Disconnect Components:** Remove the driveshaft, shift linkage, and any electrical connectors.
– **Unbolt the Transmission:** Unscrew the bolts securing the transmission to the engine and carefully lower it using the transmission jack.
#### 3. **Disassemble the Gear Set:**
– **Remove the transmission Case:** Once the transmission is on a workbench, carefully remove the outer casing.
– **Take Photos:** As you disassemble, take photos of each step to help you remember how to reassemble.
– **Remove Gears:** Use a gear puller if necessary to carefully remove gears and bearings. Keep parts organized.
#### 4. **Inspect Components:**
– **Check for Damage:** Look for worn gears, damaged bearings, or any metal shavings which indicate wear.
– **Measure Parts:** Use a micrometer or caliper to check the dimensions of gears and bearings against specifications in the service manual.
#### 5. **Replace Worn Parts:**
– **Order New Parts:** Based on your inspection, order any necessary replacement parts.
– **Install New Bearings and Seals:** Ensure that they are properly seated and lubricated.
#### 6. **Reassemble the Gear Set:**
– **Follow Your Photos:** Reassemble in the reverse order of disassembly.
– **Torque Specs:** Use a torque wrench to tighten all bolts to the manufacturer’s specifications found in the service manual.
#### 7. **Reinstall the Transmission:**
– **Align
and Secure:** Lift the transmission back into place and secure it to the engine with bolts.
– **Reconnect Components:** Reattach the driveshaft, shift linkage, and electrical connectors.
– **Refill transmission Fluid:** Use a funnel to refill the transmission with the appropriate fluid.
#### 8. **Test the Vehicle:**
– **Reconnect the Battery:** Put the negative terminal back on.
– **Start the Engine:** Check for any leaks and ensure everything is functioning properly.
– **Test Drive:** Take the car for a short drive to ensure that the transmission operates smoothly.
### Final Notes:
– **Consult the Manual:** The manufacturer’s service manual is your best resource for specific instructions and specifications.
– **Take Your Time:** Don’t rush through the process; precision is crucial in mechanical work.
– **Ask for Help:** If you encounter challenges, don’t hesitate to reach out to someone with more experience.
Good luck with your overhaul!
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