SUBARU LEGACY 1996 Service Repair Manual

Symptom and possible cause Remedy
5. Noises when cornering


1Damaged differential gear. Replace.


2Excessive wear or damage of thrust washer. Replace.


3Broken pinion mate shaft. Replace.


4Seized or damaged side bearing. Replace.
6. Gear noises
Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken for noises
from differential assembly, be careful in checking them. Inspection methods to locate noises include coasting, accelerating, cruising,
and jacking-up all four wheels. Perform these inspections according to condition of trouble. When listening to noises, shift gears into
four wheel drive and fourth speed position, trying to pick up only differential noise.


1Improper tooth contact of hypoid gear. Readjust or replace hypoid gear set.


2Improper backlash for hypoid gear. Readjust.


3Scored or chipped teeth of hypoid gear. Replace hypoid gear set.


4Seized hypoid gear. Replace hypoid gear set.


5Improper preload for front or rear bearings. Readjust.


6Seized, scored, or chipped front or rear bearing. Replace.


7Seized, scored, or chipped side bearing. Replace.


8Vibrating differential carrier. Replace.
2. Propeller Shaft
Symptom and possible cause Remedy
1. Vibration of propeller shaft
Vibration is caused by propeller shaft during operation and is transferred to vehicle body. Generally vibration increase in proportion to
vehicle speed.


1Worn or damaged universal joint. Replace.


2Unbalanced propeller shaft due to bend or dent. Replace.


3Loose installation of propeller shaft. Retighten.


4Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
2. Tapping when starting and noise while cruising, caused by propeller shaft.


1Worn or damaged universal joint. Replace.


2Worn spline of sleeve yoke. Replace.


3Loose installation of propeller shaft. Retighten.


4Loose installation of joint. Replace.


5Worn or damaged center bearing and damaged center mount-
ing rubber.Replace.
NOTE:
Vibration while cruising may be caused by an unbalanced
tire, improper tire inflation pressure, improper wheel
alignment, etc.
41
3-4DIAGNOSTICS
1. Rear Differential - 2. Propeller Shaft

42
3-4DIAGNOSTICS
2. Propeller Shaft

1. Suspension
A: SPECIFICATIONS
1. STABILIZER
ModelBar dia. mm (in)
Front Rear
Sedan2200 cc 19 (0.75) 15 (0.59)
2500 cc 20 (0.79) 16 (0.63)
Wagon2200 cc 19 (0.75) 15 (0.59)
2500 cc 20 (0.79) 16 (0.63)
OUTBACK2200 cc 20 (0.79) 18 (0.71)
2500 cc 20 (0.79) 18 (0.71)
B: WHEEL ALIGNMENT
Sedan Wagon OUTBACK
FWD AWD FWD AWD AWD
FrontCamber
(tolerance: ±0°30′)0°05′0°05′0°05′0°05′0°20′
Caster
(tolerance: ±1°)3°05′3°05′3°05′3°05′2°50′
Toe-in mm (in) 0±3 (0±0.12) Total toe angle: 0°±20′
Kingpin angle (tolerance: ±1°) 14°15′14°15′14°15′14°15′13°30′
Wheel arch height
[tolerance:
+12
24mm (+0.47
0.94in)] mm (in)385 (15.16) 385 (15.16) 385 (15.16) 385 (15.16) 420 (16.54)
RearCamber
(tolerance: ±0°45′)0°55′1° 0°45′0°55′0°35′
Toe-in mm (in) 0±3 (0±0.12) Total toe angle: 0°±20′
Wheel arch height
[tolerance:
+12
24mm (+0.47
0.94in)] mm (in)369 (14.53) 369 (14.53) 379 (14.92) 379 (14.92) 419 (16.50)
Thrust angle 0°±20′
2
4-1SPECIFICATIONS AND SERVICE DATA
1. Suspension

B4M0182A
NOTE:

Front and rear toe-ins and front camber can be adjusted.
If toe-in or front camber tolerance exceeds specifications,
adjust toe-in and camber to the specification.

The other items indicated in the specification table can-
not be adjusted. If the other items exceeds specifications,
check suspension parts and joint portions of body suspen-
sion parts for deformities; and replace with new ones as
required.
3
4-1SPECIFICATIONS AND SERVICE DATA
1. Suspension

1. Conventional Suspension
1. FRONT SUSPENSION
B4M0765A
1Front crossmember

2Bolt ASSY
3Housing
4Washer
5Stop rubber (Rear)
6Rear bushing
7Stop rubber (Front)
8Ball joint
9Transverse link
10Cotter pin
11Front bushing
12Stabilizer link
13Clamp
14Bushing (2200 cc model)
15Stabilizer (2200 cc model)
16Jack-up plate
17Dust seal
18Strut mount

19Spacer
20Upper spring seat
21Rubber seat
22Dust cover
23Helper
24Coil spring
25Damper strut
26Adjusting bolt
27Castle nut
28Self-locking nut
29Adapter front crossmember
(OUTBACK model)

30Clip (OUTBACK model)
31Bushing
(2500 cc and OUTBACK model)

32Clamp
(2500 cc and OUTBACK model)
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 18±5 (1.8±0.5, 13.0±3.6)
T2: 20±6 (2.0±0.6, 14.5±4.3)
T3: 25±4 (2.5±0.4, 18.1±2.9)
T4: 29±5 (3.0±0.5, 21.7±3.6)
T5: 39 (4, 29)
T6: 44±6 (4.5±0.6, 32.5±4.3)
T7: 49±10 (5.0±1.0, 36±7)
T8: 54±5 (5.5±0.5, 39.8±3.6)
T9: 98±15 (10.0±1.5, 72±11)
T10:152±20 (15.5±2.0, 112±14)
T11:186±10 (19.0±1.0, 137±7)
T12:245±49 (25.0±5.0, 181±36)
4
4-1COMPONENT PARTS
1. Conventional Suspension

2. REAR SUSPENSION (AWD MODEL)
B4M0766A
1Stabilizer

2Stabilizer bracket

3Stabilizer bushing

4Clamp

5Floating bushing

6Stopper

7Stabilizer link

8Rear lateral link

9Bushing (C)

10Bushing (A)

11Front lateral link

12Bushing (B)

13Trailing link rear bushing

14Trailing link

15Trailing link front bushing
16Trailing link bracket

17Cap (Protection)

18Washer

19Rear crossmember

20Strut mount cap

21Strut mount

22Rubber seat upper

23Dust cover

24Coil spring

25Helper

26Rubber seat lower

27Damper strut

28Self-locking nut

29Crossmember reinforcement
lower (Sedan model)

30Adapter rear crossmember
(OUTBACK model)
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 20±6 (2.0±0.6, 14.5±4.3)
T2: 25±7 (2.5±0.7, 18.1±5.1)
T3: 44±6 (4.5±0.6, 32.5±4.3)
T4: 59±10 (6.0±1.0, 43±7)
T5: 98±15 (10.0±1.5, 72±11)
T6: 98±20 (10.0±2.0, 72±14)
T7: 113±15 (11.5±1.5, 83±11)
T8: 127±20 (13.0±2.0, 94±14)
T9: 137±20 (14.0±2.0, 101±14)
T10:196
+39
10(20.0+4.0
1.0, 145+29
7)
5
4-1COMPONENT PARTS
1. Conventional Suspension

3. REAR SUSPENSION (FWD MODEL)
B4M0185A
1Stabilizer

2Stabilizer bracket

3Stabilizer bushing

4Clamp

5Stabilizer link

6Adjusting bolt

7Adjusting wheel

8Rear lateral link

9Bushing (D)

10Bushing (A)

11Front lateral link

12Self-locking nut

13Washer

14Cap (Protection)
15Trailing link rear bushing

16Trailing link

17Trailing link front bushing

18Trailing link bracket

19Crossmember

20Strut mount cap

21Strut mount

22Rubber seat upper

23Dust cover

24Coil spring

25Helper

26Rubber seat lower

27Damper strut
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 20±6 (2.0±0.6, 14.5±4.3)
T2: 25±7 (2.5±0.7, 18.1±5.1)
T3: 44±6 (4.5±0.6, 32.5±4.3)
T4: 59±10 (6.0±1.0, 43±7)
T5: 98±20 (10.0±2.0, 72±14)
T6: 113±15 (11.5±1.5, 83±11)
T7: 127±20 (13.0±2.0, 94±14)
T8: 137±20 (14.0±2.0, 101±14)
T9: 196
+39
10(20.0+4.0
1.0, 145+29
7)
6
4-1COMPONENT PARTS
1. Conventional Suspension

1. On-car Services
A: WHEEL ALIGNMENT
Check, adjust and/or measure wheel alignment in accor-
dance with procedures indicated below:
1. Wheel arch height (Front and rear)
2. Camber (Front and rear)
3. Caster (Front)
4. Front toe-in
5. Rear toe-in
6. Thrust angle (Rear)
7. Wheel steering angle






7
4-1SERVICE PROCEDURE
1. On-car Services

1. WHEEL ARCH HEIGHT
1) Adjust tire pressure to specifications.
2) Set vehicle under“curb weight”conditions. (Empty lug-
gage compartment, install spare tire, jack, service tools,
and top up fuel tank.)
3) Set steering wheel in a wheel-forward position.
4) Suspend thread from wheel arch (point“A”in figure
below) to determine a point directly above center of
spindle.
5) Measure distance between measuring point and center
of spindle.
B4M0566A
VehiclesSpecified wheel arch height mm (in)
Front Rear
SedanFWD 385
+12
24(15.16+0.47
0.94) 369+12
24(14.53+0.47
0.94)
AWD 385
+12
24(15.16+0.47
0.94) 369+12
24(14.53+0.47
0.94)
WagonFWD 385
+12
24(15.16+0.47
0.94) 379+12
24(14.92+0.47
0.94)
AWD 385
+12
24(15.16+0.47
0.94) 379+12
24(14.92+0.47
0.94)
OUTBACK AWD 420
+12
24(16.54+0.47
0.94) 419+12
24(16.50+0.47
0.94)
8
4-1SERVICE PROCEDURE
1. On-car Services

B4M0567A
2. CAMBER AND CASTER

Inspection
1) Place front wheel on turning radius gauge. Make sure
ground contacting surfaces of front and rear wheels are set
at the same height.
2) Set ST into the center of the wheel, and then install the
wheel alignment gauge.
ST 927380000 ADAPTER
NOTE:
Refer to the“SPECIFICATIONS AND SERVICE DATA”for
the camber and caster values.

Front camber adjustment
1) Loosen two self-locking nuts located at lower front por-
tion of strut.
CAUTION:

When adjusting bolt needs to be loosened or
tightened, hold its head with a wrench and turn self-
locking nut.

Discard loosened self-locking nut and replace with a
new one.
B4M0189A
2) Turn camber adjusting bolt so that camber is set at the
specification.
NOTE:
Moving the adjusting bolt by one scale graduation changes
camber by approximately 0°10′.
9
4-1SERVICE PROCEDURE
1. On-car Services