SUBARU LEGACY 1997 Service Repair Manual

2. 2500 cc
B4M0773A

1O-ring


2Baffle plate (FTJ)


3Spring pin


4Outer race (FTJ)


5Snap ring


6Trunnion


7Free ring


8Circlip


9Boot band

10Boot (FTJ)


11Boot (BJ)


12BJ ASSY


13Baffle plate


14Oil seal (IN)


15Snap ring


16Bearing


17Housing


18Oil seal (OUT)

19Tone wheel


20Hub bolt


21Hub


22Axle nut
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 13±3 (1.3±0.3, 9.4±2.2)
T2: 186±20 (19±2, 137±14)
6
4-2COMPONENT PARTS
1. Front Axle

2. Rear Axle
1. AWD MODEL
B4M0704A

1Baffle plate (DOJ)


2Outer race (DOJ)


3Snap ring


4Inner race


5Ball


6Cage


7Circlip


8Boot band


9Boot (DOJ)

10Boot (BJ)


11BJ ASSY


12Oil seal (IN. No. 2)


13Oil seal (IN. No. 3)


14Housing


15Bearing


16Snap ring


17Oil seal (OUT)


18Tone wheel

19Hub bolt


20Hub


21Axle nut
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 13±3 (1.3±0.3, 9.4±2.2)
T2: 186±20 (19±2, 137±14)
7
4-2COMPONENT PARTS
2. Rear Axle

2. FWD MODEL
G4M0213

1Hub cap


2O-ring


3Axle nut


4Washer

5Hub unit


6SpindleTightening torque: N⋅m (kg-m, ft-lb)
T: 186±20 (19±2, 137±14)
8
4-2COMPONENT PARTS
2. Rear Axle

1. Front Axle
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands, and
remove front wheels.
G4M0214
3) Unlock axle nut.
4) Remove axle nut using a socket wrench.
CAUTION:
Be sure to loose and retighten axle nut after removing
wheel from vehicle. Failure to follow this rule may dam-
age wheel bearings.
G4M0215
5) Remove stabilizer link.
G4M0216
6) Remove DOJ from transmission spindle.
7) Remove front drive shaft assembly from hub. If it is hard
to remove, use STs.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
Be careful not to damage oil seal lip when removing
front drive shaft.
When replacing front drive shaft, also replace inner
oil seal.
8) Remove disc brake caliper from housing, and suspend
it from strut using a wire.
9
4-2SERVICE PROCEDURE
1. Front Axle

G4M0217
9) Remove disc rotor from hub.
If disc rotor seizes up within hub, drive disc rotor out by
installing an 8-mm bolt in screw hole on the rotor.
G4M0218
10) Remove cotter pin and castle nut which secure tie-rod
end to housing knuckle arm.
G4M0219
11) Using a puller, remove tie-rod ball joint from knuckle
arm.
G4M0220
12) On A.B.S. equipped models, remove A.B.S. sensor
assembly and harness in advance.
CAUTION:
Be sure to use soft jaws (such as aluminum plates)
when placing the mating surfaces of housing and strut
in a vise.
G4M0221
13) Remove transverse link ball joint from housing.
10
4-2SERVICE PROCEDURE
1. Front Axle

G4M0222
14) After scribing an alignment mark on camber adjusting
bolt head, remove bolts which connect housing and strut,
and disconnect housing from strut.
G4M0223
B: DISASSEMBLY
1) Using ST1, support housing and hub securely.
2) Attach ST2 to housing and drive hub out.
ST1 927080000 HUB STAND
ST2 927060000 HUB REMOVER
G4M0224
If inner bearing race remains in the hub, remove it with a
suitable tool (commercially available).
CAUTION:
Be careful not to scratch polished area of hub.
Be sure to install inner race on the side of outer race
from which it was removed.
G4M0225
3) Remove disc cover from housing.
4) Using a standard screwdriver, remove outer and inner
oil seals.
CAUTION:
Do not use old oil seals.
11
4-2SERVICE PROCEDURE
1. Front Axle

H4M1001
5) Using flat bladed screwdriver, remove snap ring.
G4M0227
6) Using ST1, support housing securely.
7) Using ST2, press inner race to drive out outer bearing.
ST1 927400000 HOUSING STAND
ST2 927100000 BEARING REMOVER
CAUTION:
Do not remove outer race unless it is faulty.
Discard outer race after removal.
Do not replace inner or outer race separately;
always replace as a unit.
8) Loosen bolts which secure tone wheel to hub. Remove
tone wheel (only vehicle equipped with A.B.S.).
G4M0228
9) Using ST and a hydraulic press, drive hub bolts out.
ST 927080000 HUB STAND
CAUTION:
Be careful not to hammer hub bolts. This may deform
hub.
H4M1002A
C: INSPECTION
Check the removed parts for wear and damage. If
defective, replace with new ones.
CAUTION:
If bearing is faulty, replace it as a bearing set.
Be sure to replace oil seal at every overhaul.
12
4-2SERVICE PROCEDURE
1. Front Axle

G4M0230
D: ASSEMBLY
1) Attach hub to ST securely.
ST 927080000 HUB STAND
2) Using a hydraulic press, press new hub bolts into place.
CAUTION:
Be sure to press hub bolts until their seating surfaces
contact the hub.
NOTE:
Use 12 mm (0.47 in) dia. holes in HUB STAND to prevent
bolts from tilting.
G4M0231
3) Remove foreign particles (dust, rust, etc.) from mating
surfaces of hub and tone wheel, and install tone wheel to
hub (only vehicle equipped with A.B.S.).
CAUTION:
Be careful not to damage tone wheel teeth.
NOTE:
Ensure tone wheel closely contacts hub.
4) Clean dust or foreign particles from inside the housing.
G4M0232
5) Using ST1 and ST2, press a new bearing into place.
ST1 927400000 HOUSING STAND
ST2 927100000 BEARING REMOVER
CAUTION:
Always press outer race when installing bearing.
Be careful not to remove plastic lock from inner race
when installing bearing.
Charge bearing with new grease when outer race is
not removed.
6) Install snap ring in its groove.
NOTE:
Make sure to install it firmly to groove.
13
4-2SERVICE PROCEDURE
1. Front Axle

G4M0233
7) Using ST1 and ST2, press outer oil seal until it contacts
the bottom of housing.
ST1 927410000 OIL SEAL INSTALLER
ST2 927400000 HOUSING STAND
G4M0234
8) Using ST1 and ST2, press inner oil seal until it contacts
circlip.
ST1 927410000 OIL SEAL INSTALLER
ST2 927400000 HOUSING STAND
9) Invert ST and housing.
ST 927400000 HOUSING STAND
10) Apply sufficient grease to oil seal lip.
Specified grease:
SHELL 6459N
CAUTION:
If specified grease is not available, remove bearing
grease and apply Auto Rex A instead.
Do not mix different types of grease.
11) Install disc cover to housing the three bolts.
Tightening torque:
14±4 N⋅m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
G4M0235
12) Attach hub to ST1 securely.
13) Clean dust or foreign particles from the polished sur-
face of hub.
14) Using ST2, press bearing into hub by driving inner
race.
ST1 927080000 HUB STAND
ST2 927120000 HUB INSTALLER
14
4-2SERVICE PROCEDURE
1. Front Axle

E: INSTALLATION
1) Install transverse link ball joint to housing.
Tightening torque:
44±6 N⋅m (4.5±0.6 kg-m, 32.5±4.3 ft-lb)
2) While aligning alignment mark on camber adjusting bolt
head, connect housing and strut.
CAUTION:
Use a new self-locking nut.
Tightening torque:
147±15 N⋅m (15±1.5 kg-m, 108±11 ft-lb)
3) Install speed sensor and harness on housing (only
vehicle equipped with A.B.S.).
4) Install disc rotor on hub.
5) Install disc brake caliper on housing.
Tightening torque:
59±10 N⋅m (6±1 kg-m, 43±7 ft-lb)
6) Install front drive shaft. <Ref. to 4-2 [W4E1].>
7) Connect stabilizer link.
G4M0236
8) Install tie-rod end ball joint on housing knuckle arm.
Tightening torque:
27.0±2.5 N⋅m (2.75±0.25 kg-m, 19.9±1.8 ft-lb)
G4M0237
9) While depressing brake pedal, tighten axle nut and lock
it securely.
Tightening torque:
186±20 N⋅m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
Use a new axle nut.
Always tighten axle nut before installing wheel on
vehicle. If wheel is installed and comes in contact with
ground when axle nut is loose, wheel bearings may be
damaged.
Be sure to tighten axle nut to specified torque. Do
not overtighten it as this may damage wheel bearing.
15
4-2SERVICE PROCEDURE
1. Front Axle