ABS SUBARU LEGACY 1999 Service Repair Manual

1. Clutch System
Symptom Possible cause Corrective
1. Clutch slippage.
It is hard to perceive clutch slippage in the early stage,
but pay attention to the following symptoms
IEngine revs up when shifting.
IHigh speed driving is impossible; especially rapid
acceleration impossible and vehicle speed does not
increase in proportion to an increase in engine speed.
IPower falls, particularly when ascending a slope,
and there is a smell of burning of the clutch facing.
IMethod of testing: Put the vehicle in stationary con-
dition with parking brake fully applied. Disengage the
clutch and shift the transmission gear into the first.
Gradually allow the clutch to engage while gradually
increasing the engine speed. The clutch function is
satisfactory if the engine stalls. However, the clutch is
slipping if the vehicle does not start off and the engine
does not stall.(a) No clutch pedal play Readjust.
(b) No release lever end play Readjust.
(c) Clutch facing smeared by oil Replace.
(d) Worn clutch facing Replace.
(e) Deteriorated diaphragm spring Replace.
(f) Distorted pressure plate or flywheel Correct or replace.
(g) Defective release bearing holder Correct or replace.
(h) Defective pedal and cable system Correct or replace.
2. Clutch drags.
As a symptom of this trouble, a harsh scratching noise
develops and control becomes quite difficult when
shifting gears. The symptom becomes more apparent
when shifting into the first gear. However, because
much trouble of the this sort is due to defective syn-
chronization mechanism, carry out the test as
described after.

It may be judged as insufficient disengagement of
clutch if any noise occurs during this test.(a) Excessive clutch pedal play Readjust.
(b) Excessive clutch release lever play Readjust.
(c) Worn or rusty clutch disc hub spline Replace clutch disc.
(d) Excessive deflection of clutch disc
facingCorrect or replace.
(e) Seized crankshaft pilot needle bearing Replace.
(f) Malfunction of pedal and cable system Correct or replace.
(g) Cracked clutch disc facing Replace.
(h) Sticked clutch disc (smeared by oil or
water)Replace.
3. Clutch chatters.
Clutch chattering is an unpleasant vibration to the
whole body when the vehicle is just started with clutch
partially engaged.(a) Improper clutch cable routing Correct.
(b) Adhesion of oil on the facing Replace clutch disc.
(c) Weak or broken torsion spring Replace clutch disc.
(d) Defective facing contact or excessive
discReplace clutch disc defec-
tion.
(e) Warped pressure plate or flywheel Correct or replace.
(f) Loose disc rivets Replace clutch disc.
(g) Loose engine mounting Retighten or replace
mounting.
(h) Improper adjustment of pitching stop-
perAdjustment.
4. Noisy clutch
Examine whether the noise is generated when the
clutch is disengaged, engaged, or partially engaged.(a) Broken, worn or unlubricated release
bearingReplace release bearing.
(b) Insufficient lubrication of pilot bearing Apply grease.
(c) Loose clutch disc hub Replace clutch disc.
(d) Loose torsion spring retainer Replace clutch disc.
(e) Deteriorated or broken torsion spring Replace clutch disc.
5. Clutch grabs.
When starting the vehicle with the clutch partially
engaged, the clutch engages suddenly and the vehicle
jumps instead of making a smooth start.(a) Grease or oil on facing Replace clutch disc.
(b) Deteriorated cushioning spring Replace clutch disc.
(c) Worn or rusted spline of clutch disc or
mainTake off rust, apply
grease or replace clutch
shaft disc or mainshaft.
(d) Deteriorated or broken torsion spring Replace clutch disc.
(e) Loose engine mounting Retighten or replace
mounting.
(f) Deteriorated diaphragm spring Replace.
19
[K100]2-10DIAGNOSTICS
1. Clutch System

8) Extract companion flange with a puller.
G3M0035
9) Remove oil seal using ST.
ST 398527700 PULLER ASSY (T-type)
ST 499705401 PULLER ASSY (VA-type)
G3M0036
10) Fit a new oil seal using ST.
ST 498447120 OIL SEAL INSTALLER
G3M0037
11) Install companion flange.12) Tighten self-locking nut within the specified
torque range so that the turning resistance of com-
panion flange becomes the same as that before
replacing oil seal.
CAUTION:
Use a new self-locking nut.
ST 498427200 FLANGE WRENCH
Tightening torque:
T-type;
181.4
±14.7 N´m (18.50±1.50 kg-m,
133.8
±10.8 ft-lb)
VA-type;
188
±26 N´m (19.2±2.7 kg-m, 139±20 ft-lb)
G3M0034
13) Reassembling procedure hereafter is the
reverse of the disassembling.
2. SIDE OIL SEAL (T-TYPE)
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to ªNº.
3) Release the parking brake.
4) Loosen both wheel nuts.
5) Jack-up the vehicle and support it with rigid
racks.
6) Remove wheels.
7) Remove rear exhaust pipe.

8) Remove muffler.

9) Remove the ABS sensor cable clamp and park-
ing brake cable clamp from bracket.
B3M0610A
15
[W2A2]3-4SERVICE PROCEDURE
2. Rear Differential

10) Remove the ABS sensor cable clamp from the
trailing link.
B3M0611A
11) Remove the ABS sensor cable clamp and
parking brake cable guide from the trailing link.
B3M0612A
12) Remove the rear stabilizer link.
G3M0041
13) Remove the bolts which secure the trailing link
to the rear housing.
G3M0042
14) Remove the bolts which secure the front and
rear lateral link to the rear housing.
G3M0043
15) Remove crossmember reinforcement lower
(Sedan only).
16) Remove the DOJ from the rear differential by
using ST.
CAUTION:
When removing the DOJ from the rear
differential, fit tire lever to the bolt as shown in
figure so as not to damage the side bearing
retainer.
ST 208099PA100 DRIVE SHAFT REMOVER
H3M1667A
16
3-4[W2A2]SERVICE PROCEDURE
2. Rear Differential

(1) Remove the ABS sensor cable clamp and
parking brake cable clamp from bracket.
H3M1397A
(2) Remove the ABS sensor cable clamp from
the trailing link.
H3M1398A
(3) Remove the ABS sensor cable clamp and
parking brake cable guide from the trailing link.
H3M1399A
(4) Remove the rear stabilizer link.
H3M1396A
(5) Remove the bolts which secure the trailing
link to the rear housing.
G3M0042
(6) Remove the bolts which secure the front
and rear lateral link to the rear housing.
G3M0043
18
3-4[W2A3]SERVICE PROCEDURE
2. Rear Differential

4. Front Strut
A: REMOVAL
B4M1085A
(1) Dust seal
(2) Strut mount
(3) Spacer
(4) Upper spring seat
(5) Rubber seat
(6) Dust cover(7) Helper
(8) Coil spring
(9) Damper strut
(10) Adjusting bolt
(11) Self-locking nutTightening torque: N´m (kg-m, ft-lb)
T1:
20±6 (2.0±0.6, 14.5±4.3)
T2:54±5 (5.5±0.5, 39.8±3.6)
T3:152±20 (15.5±2.0, 112±14)
1) Remove wheel.
2) Depress brake pedal and hold it down using a
wooden block etc.
3) Remove union bolts from caliper.
CAUTION:
Use brake hose cap to prevent brake fluid from
escaping.
G4M0503
4) Remove brake hose clamp and disconnect
brake hose from strut. Attach brake hose to body
using gum tape.
G4M0504
5) Scribe an alignment mark on the camber
adjusting bolt which secures strut to housing.
6) Remove bolt securing the ABS sensor harness.
(ABS equipped models.)
18
4-1[W4A0]SERVICE PROCEDURE
4. Front Strut

9) Using hexagon wrench to prevent strut rod from
turning, tighten self-locking nut with ST.
ST 927760000 STRUT MOUNT SOCKET
Tightening torque:
54
±5 N´m (5.5±0.5 kg-m, 39.8±3.6 ft-lb)
G4M0507
10) Loosen the coil spring carefully.
E: INSTALLATION
1) Install strut mount at upper side of strut to body
and tighten with nuts.
Tightening torque:
20
±6 N´m (2.0±0.6 kg-m, 14.5±4.3 ft-lb)
2) Connect housing to lower side of strut.
3) Position aligning mark on camber adjusting bolt
with aligning mark on lower side bracket of strut.
CAUTION:
IWhile holding head of adjusting bolt, tighten
self-locking nut.
IBe sure to use new self-locking nut.
Tightening torque:
152
±20 N´m (15.5±2.0 kg-m, 112±14 ft-lb)
4) Install ABS sensor harness to strut. (ABS
equipped models.)
Tightening torque:
152
±20N´m (15.5±2.0 kg-m, 112±14 ft-lb)
5) Install brake hose at lower side of strut with
clamp.
6) Install union bolts which secure brake caliper to
brake hose.
Tightening torque:
18
±3 N´m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
G4M0503
CAUTION:
Be sure to bleed air from brake system.
7) Install wheels.
NOTE:
Check wheel alignment and adjust if necessary.
21
[W4E0]4-1SERVICE PROCEDURE
4. Front Strut

7. Rear Trailing Link
A: REMOVAL
H4M1066C
(1) Trailing link
(2) Front bushing
(3) Rear bushing
(4) Bracket(5) Housing
(6) Self-locking nutTightening torque: N´m (kg-m, ft-lb)
T1:
98±20 (10.0±2.0, 72±14)
T2:11 3±15 (11.5±1.5, 83±11 )
1) Loosen rear wheel nuts.
2) Lift-up vehicle, support it with safety stands
(rigid racks) and remove rear wheels.
3) Remove both rear parking brake clamp and
ABS sensor harness. (ABS equipped models.)
4) Remove bolt which secure trailing link to trailing
link bracket.
B4M0570A
5) Remove bolt which secure trailing link to rear
housing.
25
[W7A0]4-1SERVICE PROCEDURE
7. Rear Trailing Link

8. Lateral Link
A: REMOVAL
H4M1067C
(1) Crossmember
(2) Adjusting bolt
(3) Stabilizer link
(4) Rear lateral link
(5) Bushing (C)
(6) Bushing (A)
(7) Front lateral link(8) Bushing (B)
(9) Washer
(10) Cap (Protection)
(11) Trailing link
(12) Self-locking nutTightening torque: N´m (kg-m, ft-lb)
T1:
44±6 (4.5±0.6, 32.5±4.3)
T2:98±15 (10.0±1.5, 72±11 )
T3:11 3±15 (11.5±1.5, 83±11
T4:137±20 (14.0±2.0, 101±14)
1) Loosen wheel nuts. Lift-up vehicle and remove
wheel.
2) Remove stabilizers link from lateral link.
3) Remove ABS sensor harness from trailing link.
(ABS equipped models.)
4) Remove bolt securing trailing link to housing.
B4M0573A
5) Remove bolts which secure lateral link assem-
bly to rear housing.
6) Remove crossmember reinforcement lower
from crossmember. (4 door model only)
29
[W8A0]4-1SERVICE PROCEDURE
8. Lateral Link

CAUTION:
ICheck that hose clip is positioned properly.
ICheck brake hose for twisting, or excessive
tension.
IModels equipped with ABS:
Do not subject ABS sensor harness to exces-
sive tension.
6) Be sure to bleed air from brake system.
7) Lower vehicle and tighten wheel nut.
Tightening torque:
88
±10 N´m (9±1 kg-m, 65±7 ft-lb)
8) Sedan:
Install rear seat backrest and rear seat cushion.
Wagon:
Install strut cap of rear quarter trim.
NOTE:
Check wheel alignment and adjust if necessary.
35
[W9E0]4-1SERVICE PROCEDURE
9. Rear Strut

10. Rear Crossmember
A: REMOVAL
B4M0572B
(1) Crossmember
(2) Floating bushing
(3) Adjusting bolt
(4) Stopper
(5) Stabilizer link
(6) Rear lateral link
(7) Front lateral link
(8) Washer(9) Cap (Protection)
(10) Trailing link
(11) Self-locking nut
(12) Crossmember reinforcement
lower (Sedan model only)Tightening torque: N´m (kg-m, ft-lb)
T1:
25±7 (2.5±0.7, 18.1±5.1)
T2:44±6 (4.5±0.6, 32.5±4.3)
T3:98±15 (10.0±1.5, 72±11 )
T4:11 3±15 (11.5±1.5, 83±11 )
T5:127±20 (13.0±2.0, 94±14)
T6:137±20 (14.0±2.0, 101±14)
CAUTION:
Do not subject ABS sensor harness to exces-
sive tension. (ABS equipped models.)
1) Separate front exhaust pipe and rear exhaust
pipe.
2) Remove rear exhaust pipe and muffler.
3) Remove crossmember reinforcement lower.
(Sedan model only)
4) Remove rear differential. 5) Place transmission jack under rear crossmem-
ber.
G4M0544
36
4-1[W10A0]SERVICE PROCEDURE
10. Rear Crossmember