alignment SUBARU LEGACY 1995 Service Owner's Manual

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.
10
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.
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.
14
4-2SERVICE PROCEDURE
1. Front Axle

G5M0332
4) Remove steering wheel nut, then draw out steering
wheel from shaft using steering puller.
G4M0086
5) Remove universal joint bolts and then remove universal
joint.
CAUTION:
Scribe alignment marks on universal joint so that it can
be reassembled at the original serration.
6) Remove trim panel under instrument panel.
7) Disconnect connectors for ignition switch and combina-
tion switch wiring harness under instrument panel.
B4M0127A
8) Remove the two bolts under instrument panel securing
steering shaft.
9) Pull out steering shaft assembly from hole on toe board.
CAUTION:
Be sure to remove universal joint before removing
steering shaft assembly installing bolts when remov-
ing steering shaft assembly or when lowering it for
servicing of other parts.
B4M0555
B: DISASSEMBLY
Remove the four screws securing upper and lower steer-
ing column covers, and the two screws securing combina-
tion switch, then remove related parts.
NOTE:
Steering column assembly can not to be disassembled.
11
4-3SERVICE PROCEDURE
2. Tilt Steering Column

A: REMOVAL
1) Disconnect battery negative terminal.
2) Disconnect both oxygen sensor and exhaust gas tem-
perature warning sensor connectors from front exhaust
pipe assembly.
WARNING:
Be careful as exhaust pipe is hot.
3) Raise vehicle with a jack and remove front wheel.
4) Disconnect front exhaust pipe assembly.
G4M0097
5) Remove cotter pin and castle nut. Using a puller,
remove tie-rod end from knuckle arm.
G4M0098
6) Remove jack-up plate and stabilizer.
G4M0786
7) Disconnect one pipe joint A from center of gearbox
assembly, and connect a vinyl hose to it. While turning
steering wheel to the left and right, drain fluid through the
hose. Similarly, drain fluid from the other pipe joint B.
G4M0787
8) Remove lower and upper bolts from universal joint, and
remove universal joint in the upward direction.
NOTE:
Scribe alignment marks on universal joint so that it can be
reassembled at the original serration.
30
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

1. Power Steering
1. STEERING CONDITION
Heavy steering
effort in all rangeHeavy steering
effort at stand stillSteering wheel
surges when turn-
ing.Vehicle leads to
one side or the
other.Poor return of
steering wheel to
center
Pulley belt
1. Unequal length of pulley
belts
2. Adhesion of oil and
grease
3. Loose or damage of pul-
ley belt
4. Poor uniformity of pulley
belt cross section
5. Pulley belt touches to
pulley bottom
6. Poor revolution of pulleys
except oil pump pulley
7. Poor revolution of oil
pump pulley
GOOD
NOT GOOD
Adjust or replace.Fluid line
1. Folded hose
2. Flattened pipe
GOOD
NOT
GOODReform or
replace.
Tire and rim
1. Flat tire
2. Mix use of different tires
3. Mix use of different rims
4. Abnormal wear of tire
5. Unbalance of remained
grooves
6. Unbalance of tire pres-
sure
GOOD
NOT
GOODFix or replace.
Tire and rim
1. Improper tires out of
specification
2. Improper rims out of
specification
3. Tires not properly
inflated*1
GOOD
NOT GOOD
Replace or reinflate.Front alignment
1. Improper or unbalance
caster
2. Improper or unbalance
toe-in
3. Loose connection of sus-
pension
GOOD
NOT
GOODAdjust or
retighten.
Fluid
1. Low fluid level
2. Aeration
3. Dust mix
4. Deterioration of fluid
5. Poor warming-up of fluid
*2
GOOD
NOT GOOD
Refill, bleed air, replace or
instruct customer.Others
1. Damaged joint assembly
2. Unbalanced height
3. One-sided weight
GOOD
Measure steering effort.
NOT
GOODReplace, adjust or
instruct customer.
Idling speed
1. Lower idling speed
2. Excessive drop of
idling speed at start
or at turning steering
wheel *3
GOOD
NOT GOOD
Adjust or instruct customer.
*1 If tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a
condition, for example before fluid warms-up, relief valve may work before maximum turning angle.
In this case, steering effort may be heavy. When measured hydraulic pressure is normal, there is
no abnormal thing.
*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After
warming up engine, turn steering wheel from stop to stop several times to warm up fluid. Then if
steering effort reduces normally, there is no abnormal thing.
*3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to exces-
sive drop of idling when turning steering wheel. In this case, it is recommended to start the vehicle
with increasing engine speed than usual. Then if steering effort reduces normally, there is no
abnormal thing. Measure hydraulic pressure.
GOOD
Measure steering effort.








84
4-3DIAGNOSTICS
1. Power Steering

1. Entire Brake System
Trouble and possible cause Corrective action
1. Insufficient braking
(1) Fluid leakage from the hydraulic mechanismRepair or replace (cup, piston seal, piston boot, master cylinder
piston kit, pipe or hose).
(2) Entry of air into the hydraulic mechanism Bleed the air.
(3) Excessively wide shoe clearance Adjust the clearance.
(4) Wear, deteriorated surface material, adhering water or fluid
on the liningReplace, grind or clean.
(5) Improper operation of master cylinder, disc caliper, brake
booster or check valveCorrect or replace.
2. Unstable or uneven braking
(1) Fluid on the lining, drum or rotor Eliminate cause of fluid leakage, clean, or replace.
(2) Drum or rotor eccentricity Correct or replace the drum or rotor.
(3) Worn brake drum, or damage to the drum caused by sand Correct by grinding, or replace.
(4) Improper lining contact, deteriorated surface material,
improper inferior material, or wearCorrect by grinding, or replace.
(5) Deformed back plate Correct or replace.
(6) Improper tire inflation Inflate to correct pressure.
(7) Disordered wheel alignment Adjust alignment.
(8) Loosened back plate or the support installing bolts Retighten.
(9) Loosened wheel bearing Retighten to normal tightening torque or replace.
(10) Trouble in the hydraulic system Replace the cylinder, brake pipe or hose.
(11) Uneven effect of the parking brake Check, adjust, or replace the rear brake and cable system.
3. Excessive pedal stroke
(1) Entry of air into the hydraulic mechanism Bleed the air.
(2) Excessive play in the master cylinder push rod Adjust.
(3) Fluid leakage from the hydraulic mechanismRepair or replace (cup, piston seal, piston boot, master cylinder
piston kit, pipe or hose).
(4) Improperly adjusted shoe clearance Adjust.
(5) Improper lining contact or worn lining Correct or replace.
101
4-4DIAGNOSTICS
1. Entire Brake System

1. Supplemental Restraint System
“Airbag”
Airbag system wiring harness is routed on and along body
panels.
CAUTION:

All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuits.

Be careful not to damage Airbag system wiring har-
ness when repairing the body panel.
2. Body Datum Points
Various master repair locations are established as datum
points used during body repairs. In addition, guide holes,
locators and indents are provided to facilitate panel
replacement and achieve alignment accuracy.
NOTE:
Left and right datum points are all symmetrical to each
other.
2
5-1SERVICE DATA
1. Supplemental Restraint System“Airbag”- 2. Body Datum Points

1. Supplemental Restraint System
“Airbag”
Airbag system wiring harness is routed on and along body
panels.
CAUTION:

All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuits.

Be careful not to damage Airbag system wiring har-
ness when repairing the body panel.
2. Body Datum Points
Various master repair locations are established as datum
points used during body repairs. In addition, guide holes,
locators and indents are provided to facilitate panel
replacement and achieve alignment accuracy.
NOTE:
Left and right datum points are all symmetrical to each
other.
2
5-1SERVICE DATA
1. Supplemental Restraint System“Airbag”- 2. Body Datum Points

G5M0147
4. TRUNK LID OPENER
1) Remove rear seats, center pillar lower cover, floor mat,
rear arch cover and side sill cover (on the driver’s side).
2) Remove all clips which hold cable.
3) Disconnect cable from pull handle assembly.
4) Remove bolts and detach pull handle assembly.
5) Loosen bolts which hold lock assembly, and remove it.
6) Remove striker from trunk lid.
7) Disconnect cable from striker.
NOTE:

Be careful not to bend or break cable.

Basic model vehicles do not have trunk lid opener sys-
tem.
B5M0372A
B: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:

When installing cover to pull handle assembly,
observe the following:

Be careful not to catch harness.

Engage pull handle assembly pawls firmly.

After installing opener cable, ensure it moves
smoothly.

Apply a coat of grease to the rotary section of
hinges and contact surfaces of torsion bars.

Apply grease to sliding surfaces of lock assembly
and striker.
B5M0270A
C: ADJUSTMENT
1. TRUNK LID
1) To adjust left-right lid positioning, loosen bolts which
hold trunk lid to hinges.
2) To adjust up-down lid alignment, place washer(s)
between trunk lid and hinges or move trunk lock assembly
up or down.
34
5-1SERVICE PROCEDURE
2. Trunk Lid

G5M0175
B: INSTALLATION
1) Installation is in the reverse order of removal.
2) Check for alignment of front fender with hood and front
door with front fender at all points. Adjust, if necessary.
B5M0287A
9. Mud Guard and Rear Arch
Protector
A: REMOVAL
SUPPLEMENTAL RESTRAINT SYSTEM“AIRBAG”
Airbag system wiring harness is routed near the mud
guard.
CAUTION:

All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuits.

Be careful not to damage Airbag system wiring har-
ness when servicing the mud guard.
B5M0288
1. MUD GUARD
1) Jack-up vehicle to remove tire.
2) Remove screws and clips. Move mud guard toward the
center of the body and remove mud guard.
46
5-1SERVICE PROCEDURE
8. Front Fender - 9. Mud Guard and Rear Arch Protector