ac 25 procedure SUBARU TRIBECA 2009 1.G Service Workshop Manual

DI-27
Rear Differential (VA–type)
DIFFERENTIALS
•Flank contact
Check item: Backlash is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion
height adjusting washer according to the procedure for
bringing drive pinion away from hypoid driven gear.
•Toe contact (inner side contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of pinion
height adjusting washer according to the procedure
for bringing drive pinion away from hypoid driven gear.
•Heel contact (outside end contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Increase thickness of drive pin-
ion height adjusting washer in order to bring drive
pinion close to hypoid driven gear.
20) If proper tooth contact is not obtained, once
again adjust the drive pinion height and the differ-
ential side bearing preload (already mentioned)
and the hypoid gear backlash.
21) Attach a new gasket, rear cover, and ground
stay to the differential carrier.
Tightening torque:
34 N·m (3.5 kgf-m, 25.1 ft-lb)
22) Using new gaskets, install the rear differential
oil temperature switch.
Tightening torque:
60 N·m (6.1 kgf-m, 44.3 ft-lb)
AT-00209
AT-00213
AT-00210
AT-00213
AT-00211
AT-00212
DI-00477

DS-20
Front Hub Unit Bearing
DRIVE SHAFT SYSTEM
B: INSTALLATION
1) Place the disc cover between front housing and
front hub unit, and tighten the four bolts.
Tightening torque:
65 N·m (6.6 kgf-m, 47.9 ft-lb)
2) Install the front drive shaft. <Ref. to DS-24, IN-
STALLATION, Front Drive Shaft.>
3) Tighten the axle nut temporarily.
4) Install the disc rotor to hub.
5) Install the disc brake caliper to the front housing.
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
6) While depressing the brake pedal, tighten a new
axle nut (olive color) to the specified torque and
lock it securely.
Tightening torque:
240 N·m (24.5 kgf-m, 177 ft-lb)
CAUTION:
•Install the wheel after installation of axle nut.
Failure to follow this rule may damage the
wheel bearing.
•Be sure to tighten the axle nut to specified
torque. Do not overtighten it as this may dam-
age the wheel bearing.
7) After tightening the axle nut, lock it securely.
8) Install the wheel and tighten the wheel nuts to
specified torque.
Tightening torque:
110 N·m (11.2 kgf-m, 81.1 ft-lb)
C: DISASSEMBLY
Using the ST and a hydraulic press, push out the
hub bolts.
ST 28399AG000 HUB STAND
CAUTION:
•Be careful not to hammer the hub bolts. This
may deform the hub.
•Do not reuse the hub bolt.
NOTE:
Since the hub unit bearing can not be disassem-
bled, only hub bolts can be removed.
D: ASSEMBLY
1) Attach the hub to the ST securely.
ST28099PA080 HUB STAND
2) Using a press, press the new hub bolts until their
seating surfaces contact the hub.
NOTE:
Use the 12 mm (0.47 in) dia. holes in the HUB
STAND to prevent bolts from tilting.
E: INSPECTION
Refer to Front Axle for inspection procedures.
<Ref. to DS-16, INSPECTION, Front Axle.>
CAUTION:
If there is any fault in the bearing, replace hub
unit bearing.
(A) Front housing
(A)
DS-00357
DS-00048
(1) Front hub unit bearing
(1) Front hub unit bearing
ST
DS-00252
(1)
DS-00253
ST
(1)

DS-31
Rear Drive Shaft
DRIVE SHAFT SYSTEM
10) Install the snap ring in the groove on the DOJ
outer race.
NOTE:
•Assure that the balls, cage and inner race are
completely fitted in the outer race of DOJ.
•Use care not to place the matched position of
snap ring in the ball groove of outer race.
•Pull the shaft lightly and assure that the circlip is
completely fitted in the groove.
11) Apply an even coat of the specified grease [20
to 30 g (0. 71 to 1. 06 oz)] to the entire inner surface
of boot. Also apply grease to the shaft.
12) Install the DOJ boot taking care not to twist it.
NOTE:
•The inside of the larger end of DOJ boot and the
boot groove shall be cleaned so as to be free from
grease and other substances.
•When installing the DOJ boot, position the outer
race of DOJ at center of the stroke.
13) Put a new band through the clip and wind twice
in the band groove of the boot.
14) Pinch the end of band with pliers. Hold the clip
and tighten securely.
NOTE:
When tightening boot, use care so that the air with-
in the boot is appropriate.
15) Tighten the band using the ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tighten the band until it cannot be moved by hand.
16) Tap the clip with the punch provided at the end
of the ST.
ST 925091000 BAND TIGHTENING TOOL
NOTE:
Tap to an extent that the boot underneath is not
damaged.
17) Cut off the band with an allowance of about 10
mm (0.39 in) left from the clip and bend this allow-
ance over the clip.
NOTE:
Be careful so that the end of the band is in close
contact with clip.
18) Install the EBJ boot using the same procedures
as for the DOJ boot.
19) Extend and retract the DOJ repeatedly to pro-
vide an equal coating of grease.
E: INSPECTION
Check the removed parts for damage, wear, corro-
sion etc. Repair or replace if defective.
•DOJ (Double Offset Joint)
Check for seizure, corrosion, damage, wear and
excessive play.
•EBJ (high-efficiency compact ball fixed joint)
Check for seizure, corrosion, damage, wear and
excessive play.
•Shaft
Check for excessive bending, twisting, damage
and wear.
•Boot
Check for wear, warping, breakage and scratches.
•Grease
Check for discoloration and fluidity.
DS-00125
DS-00132
DS-00133

FS-6
Wheel Alignment
FRONT SUSPENSION
2. Wheel Alignment
A: INSPECTION
Check the following items before performing the wheel alignment measurement.
Check items before measuring wheel alignment:
•Tire inflation pressure
•Uneven wear of RH and LH tires, or difference of sizes
•Tire runout
•Excessive play and wear of ball joint
•Excessive play and wear of tie rod end
•Excessive play of wheel bearing
•Right and left wheel base imbalance
•Deformation and excessive play of steering link
•Deformation and excessive play of suspension parts
Check, adjust and measure the wheel alignment in accordance with the procedures indicated in the figure.
Wheel arch height (front and rear wheels)
<Ref. to FS-7, WHEEL ARCH HEIGHT, INSPECTION, Wheel Alignment.>
↓
Camber (front and rear wheels)
<Ref. to FS-8, CAMBER, INSPECTION, Wheel Alignment.>
↓
Caster (front wheel)
<Ref. to FS-9, CASTER, INSPECTION, Wheel Alignment.>
↓
Steering angle
<Ref. to FS-10, STEERING ANGLE, INSPECTION, Wheel Alignment.>
↓
Fr o nt wh ee l to e –i n
<Ref. to FS-10, FRONT WHEEL TOE–IN, INSPECTION, Wheel Alignment.>
↓
Rear wheel toe–in
<Ref. to FS-10, REAR WHEEL TOE–IN, INSPECTION, Wheel Alignment.>
↓
Thrust angle
<Ref. to FS-12, THRUST ANGLE, INSPECTION, Wheel Alignment.>

FS-10
Wheel Alignment
FRONT SUSPENSION
4. STEERING ANGLE
•INSPECTION
•ADJUSTMENT
1) Turn the tie-rod to adjust the steering angle of
both inner and outer wheels.
2) Check the toe–in.
NOTE:
Correct the boot if it is twisted.
5. FRONT WHEEL TOE–IN
•INSPECTION
Toe-in:
0±3 mm (0±0.12 in)
1) Set the toe-in gauge in the position at wheel axis
center height behind the right and left front tires.
2) Place a mark at the center of both left and right
tires, and measure distance “A” between the
marks.
3) Move the vehicle forward to rotate the tires 180°.
NOTE:
Be sure to rotate the tires in the forward direction.
4) Measure distance “B” between the left and right
marks. Find toe–in using the following equation:
A – B = Toe–in
•ADJUSTMENT
When adjusting the toe-in, adjust it to the following
value.
Toe-in:
0±2 mm (0±0.08 in)
1) Check that the left and right wheel steering an-
gles are within specification.
2) Loosen the left and right side steering tie–rod
lock nuts.
3) Turn the left and right tie–rods by equal amounts
until the toe–in is at the specification.
Both the left and right tie–rods are right–hand
threaded. To increase toe–in, turn both tie–rods
clockwise by equal amount (viewing from the inside
of vehicle).
4) Tighten the tie–rod lock nut.
Tightening torque:
85 N·m (8.7 kgf-m, 62.7 ft-lb)
NOTE:
Check and correct the tie rod boot if twisted.
6. REAR WHEEL TOE–IN
•INSPECTION
Toe-in:
2±2 mm (0.08±0.08 in)
Refer to FRONT WHEEL TOE–IN for rear toe–in
inspection procedures.
<Ref. to FS-10, FRONT WHEEL TOE–IN, IN-
SPECTION, Wheel Alignment.>
Inner wheel Outer wheel
37.0°±1.5° 32.0°±1.5°
(1) Lock nut
FS-00014
(1)
FS-00015
AB
(1) Lock nut
FS-00014
(1)

FS-15
Front Ball Joint
FRONT SUSPENSION
5. Front Ball Joint
A: REMOVAL
1) Lift-up the vehicle, and remove the front wheels.
2) Remove the both sides of stabilizer bracket.
3) Pull out the pin from ball stud, remove the castle
nut, and extract the ball stud from front arm.
4) Remove the bolt installing ball joint to housing.
5) Extract the ball joint from housing.
B: INSTALLATION
1) Insert the ball joint into housing.
Tightening torque (Bolt):
50 N·m (5.1 kgf-m, 36.9 ft-lb)
CAUTION:
Do not apply grease to the tapered portion of
ball stud.
2) Install the ball joint into front arm.
Tightening torque (castle nut):
Front arm
45 N·m (4.6 kgf-m, 33.2 ft-lb)
3) Retighten the castle nut further up to 60° until the
hole in the ball stud is aligned with a slot in castle
nut. Then, insert a new cotter pin and bend it
around the castle nut.
4) Install the stabilizer bracket.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
5) Install the front wheels.
C: INSPECTION
1) Measure the play of the ball joint using the fol-
lowing procedures. Replace with a new part if the
play exceeds specification.
(1) With 980 N (100 kgf, 220 lb) loaded in direc-
tion shown in the figure, measure the length
21.
(2) With 980 N (100 kgf, 220lb) loaded in direc-
tion shown in the figure, measure the length
22.
(3) Determine free play using the following for-
mula.
S = 22 – 21(4) Replace with a new part if the play exceeds
specification.
FRONT BALL JOINT
Specification for replacement S:
Less than 0.3 mm (0.012 in)
2) If the play is within specification, visually check
the dust cover.
3) Remove the ball joint and cover, and check for
wear, damage or cracks. If any damage is found,
replace the corresponding part.
4) If the dust cover is damaged, replace with a new
ball joint.
FS-00202
FS-00115
FS-00035
FS-00036

FS-20
Front Strut
FRONT SUSPENSION
C: DISASSEMBLY
1) Using a coil spring compressor, compress the
coil spring.
2) Using the ST, remove the self–locking nut.
ST 20399AG000 STRUT MOUNT SOCKET
3) Remove the strut mount, spacer and upper
spring seat from strut.
4) Gradually decrease the compression force of
compressor, and remove the coil spring.
5) Remove the dust cover and helper spring.
D: ASSEMBLY
1) Before installing the coil spring, strut mount, etc.
on strut, check for the presence of air in the damp-
ening force generating mechanism of the strut
since air prevents proper dampening force produc-
tion.
2) Checking for presence of air
(1) Place the strut vertically with the piston rod
facing up.
(2) Move the piston rod to the center of its entire
stroke.
(3) While holding the piston rod end with fin-
gers, move the rod up and down.
(4) If the piston rod moves more than 10 mm
(0.39 in) in the former step, purge air from the
strut.
3) Air purging procedure
(1) Place the strut vertically with the piston rod
facing up.
(2) Fully extend the piston rod.
(3) With the piston rod fully extended, place the
piston rod side down. The strut must stand ver-
tically.
(4) Fully retract the piston rod.
(5) Repeat 3 or 4 times from the step (1).
NOTE:
After purging air from the strut, be sure to place the
strut with the piston rod facing up. If the strut is laid
down for any reason, check for the entry of air in ac-
cordance with “Checking for presence of air”
4) Using a coil spring compressor, compress the
coil spring.
NOTE:
Make sure that the vertical install direction of the
coil spring is as shown in the figure.
5) Set the coil spring correctly so that its end face
seats well in the spring seat as shown in the figure.
6) Install the helper and dust cover to the piston
rod.
FS-00040
FS-00041
ST
(1) Place the flat end on the top side.
(2) Identification paint
(1) Coil spring end face
FS-00216
(2)
(1)
FS-00043
(1)

PS-16
Tilt Steering Column
POWER ASSISTED SYSTEM (POWER STEERING)
B: INSTALLATION
1) Insert the end of the steering shaft into the toe
board.
2) With the tilt lever secured, tighten the steering
shaft mounting bolts under instrument panel.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
3) Connect all the connectors under the instrument
panel.
4) Connect the airbag system connector at the har-
ness spool.
NOTE:
Make sure to apply double lock.
5) Install the instrument panel lower cover with tilt
lever held in the lowered position.
6) Install the universal joint. <Ref. to PS-13, IN-
STALLATION, Universal Joint.>
7) Align the center position of the roll connector.
<Ref. to AB-24, ADJUSTMENT, Roll Connector.>
8) Install the steering wheel. <Ref. to PS-12, IN-
STALLATION, Steering Wheel.>
CAUTION:
Insert the roll connector guide pin into the
guide hole on lower end of steering wheel sur-
face to prevent damage.
C: DISASSEMBLY
Remove the two screws securing the upper steer-
ing column covers, and the two screws securing
the combination switch, and then remove related
parts.
D: ASSEMBLY
Insert the combination switch to the upper column
shaft, and install the upper column cover. Then
route the ignition key harness and combination
switch harness between the column cover mount-
ing bosses.
Tightening torque:
1.2 N·m (0.12 kgf-m, 0.9 ft-lb)
CAUTION:
Do not overtorque the screw.
E: INSPECTION
1. BASIC INSPECTION
Measure the overall length of steering column. If
not within specification, replace it.
Overall length L:
Specification
917.5 +1.3 mm –0.3 mm (36.12 +0.051 in –0.020 in )
2. INSPECTION OF AIRBAG SYSTEM
WARNING:
Refer to “Airbag System” for airbag inspection
procedure. <Ref. to AB-4, CAUTION, General
Description.>
PS-00734
L

PS-44
Oil Pump
POWER ASSISTED SYSTEM (POWER STEERING)
E: INSPECTION
1. BASIC INSPECTION
Perform the following inspection procedures and replace faulty parts.
2. SERVICE LIMIT
Make a measurements as follows. If it exceeds the
service limit, replace with a new one.
CAUTION:
•When securing the oil pump on a vise, hold
the oil pump with the least possible force be-
tween two pieces of wood.
•Do not set the outside of flow control valve or
pulley on a vise; otherwise outside or pulley
might be deformed. Select properly sized wood
pieces.
1) Play of the pulley shaft
Condition:
P: When applying the force of 9.8 N (1.0 kgf,
2.2 lb)
Service limit:
Play in the radial direction (Direction )
Less than 0.2 mm (0.008 in)
Axial play (Direction )
Less than 0.6 mm (0.024 in)
2) Deflection of the pulley groove
Service limit:
Less than 1.0 mm (0.039 in)
NOTE:
Read the value for one surface of V ditch, and then
the value for another off the dial.
No. Parts Inspection Corrective action
1Oil pump
(Exterior)
(1) Crack, damage or oil leakage Replace the oil pump with a new one.
(2) Play of pulley shaft
Measure the radial play and axial play.
If any of these exceeds the service limit, replace the oil pump
with a new one.
2Pulley
(1) Damage Replace with a new part.
(2) BendMeasure the V groove deflection.
If it exceeds the service limit, replace the pulley with a new one.
3Oil pump
(Interior)
(1) Faulty or seized of vane pumpCheck the rotating resistance of pulley.
If it exceeds the service limit, replace the oil pump with new one.
(2) Bend in the shaft or damage
to bearing
If the a string is wrapped on the pulley and rotated, and the oil
pump emits a noise that is markedly different in tone and loud-
ness from a sound of a new oil pump, replace the oil pump with
a new one.
4O–ring Cracking or deterioration Replace with a new part.
5Bracket Cracking Replace with a new part.
(1) Dial gauge
PS-00145P
(1)
(1) Dial gauge
(1) Dial gauge
PS-00146P
(1)
PS-00147

RS-12
Rear Shock Absorber
REAR SUSPENSION
6. Rear Shock Absorber
A: REMOVAL
1) Remove the strut cap of quarter trim.
2) Lift-up the vehicle, and then remove the rear
wheels.
3) Remove the nut and detach the rear stabilizer link.
4) Remove the bolts on the bottom side of the
shock absorber.
5) Detach the rear lateral link.
6) Remove the nuts of the shock absorber mount.
7) Remove the shock absorber.
B: INSTALLATION
NOTE:
•Be sure to use a new self-locking nut.
•Always tighten the stabilizer bushing in the state
where the vehicle is at curb weight and the wheels
are in full contact with the ground.
1) Install in the reverse order of removal.
CAUTION:
Attach so that the protrusion on the top of the
mount is pointed towards the front of the vehicle.
Tightening torque:
Refer to “COMPONENT” of “General Descrip-
tion” for the tightening torque. <Ref. to RS-3,
COMPONENT, General Description.>
2) Check the wheel alignment and adjust it if nec-
essary.
C: DISASSEMBLY
Refer to “Front Strut” for disassembly procedure.
<Ref. to FS-20, DISASSEMBLY, Front Strut.>
D: ASSEMBLY
Refer to “Front Strut” for installation procedures.
<Ref. to FS-20, ASSEMBLY, Front Strut.>
E: INSPECTION
Refer to “Front Strut” for inspection procedures.
<Ref. to FS-21, INSPECTION, Front Strut.>
RS-00185
RS-00186
RS-00187
RS-00188
(1) Mount
(2) Protrusion por tion
(3) Front side of vehicle