fuse SUBARU LEGACY 1996 Service Workshop Manual

G3M1050
19) Install rear cover and tighten bolts to specified torque.
Tightening torque:
29±5 N⋅m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
F: INSTALLATION
To install, reverse the removal sequence.
1) Install the air breather cap tapping with a plastic ham-
mer.
CAUTION:
Be sure to install new air breather cap.
2) Position front member on body by passing it under park-
ing brake cable and securing to rear differential.
NOTE:
When installing rear differential front member, do not con-
fuse the installation sequence of the upper and lower stop-
pers.
G3M1026
3) Install DOJ of rear drive shaft into rear differential. to 3-4 [W2A2].>
ST 28099PA090 SIDE OIL SEAL PROTECTOR
G3M1051
4) Installing procedure hereafter is in the reverse order of
removal.
5) After installation, fill differential carrier with gear oil to
the upper plug level.
CAUTION:
Apply fluid packing to plug.
Fluid packing:
THREE BOND 1205 or equivalent
Oil capacity:
0.8
(0.8 US qt, 0.7 Imp qt)
Tightening torque:
44±4 N⋅m (4.5±0.4 kg-m, 32.5±2.9 ft-lb)
37
3-4SERVICE PROCEDURE
2. Rear Differential

G3M1029
B: INSTALLATION
To install, reverse the removal sequence.
1) Position front member on body by passing it under park-
ing brake cable and securing to rear differential.
G3M0101
NOTE:
When installing rear differential front member, do not con-
fuse the installation sequence of the stopper.
G3M1026
2) Insert DOJ of rear drive shaft into rear differential.
ST 28099PA090 SIDE OIL SEAL PROTECTOR
CAUTION:
Before inserting, replace the differential side oil seal
and the circlip at the end of the spline shaft with a new
one.
3) Installing procedure hereafter is in the reverse order of
removal.
39
3-4SERVICE PROCEDURE
3. Rear Differential Front Member

G4M0995
CAUTION:
Be careful not to damage side bearing retainer. Always
use bolt as shown in figure, as supporting point for ST
during removal.
ST 28099PA100 DRIVE SHAFT REMOVER
G4M0247
10) Remove axle nut and drive shaft. If it is hard to
remove, use ST1 and ST2.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
Be careful not to damage oil seal lip when removing
rear drive shaft.
When rear drive shaft is to be replaced, also replace
inner oil seal with a new one.
G4M0281
B: DISASSEMBLY
1. AWD MODEL
1) Straighten bent claw of larger end of DOJ boot.
2) Loosen band by means of screwdriver or pliers with
care of not damaging boot.
3) Remove boot band on the small end of DOJ boot in the
same manner.
4) Remove the larger end of DOJ boot from DOJ outer
race.
G4M0282
5) Pry and remove round circlip located at the neck of DOJ
outer race with a screwdriver.
B4M0227A
6) Take out DOJ outer race from shaft assembly.
7) Wipe off grease and take out balls.
CAUTION:
The grease is a special grease (grease for constant
velocity joint). Do not confuse with other greases.
NOTE:
Disassemble exercising care not to lose balls (6 pcs).


1Outer race


2Grease
30
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

8) To remove the cage from the inner race, turn the cage
by a half pitch to the track groove of the inner race and shift
the cage.
9) Remove snap ring, which fixes inner race to shaft, by
using pliers.
10) Take out DOJ inner race.
11) Take off DOJ cage from shaft and remove DOJ boot.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to prevent
boot from scratches.
12) Remove UFJ/BJ boot in the same procedure as steps
1) to 3).
13) Thus, disassembly of axle is completed, but UFJ/BJ is
unable to be disassembled.
G4M0281
2. FWD MODEL
1) Remove both DOJ boot bands.
2) Loosen band by means of screwdriver or pliers taking
care to not damage the boot.
3) Remove the larger end of DOJ boot from DOJ outer
race.
G4M0282
4) Pry and remove round circlip located at the neck of DOJ
outer race with a screwdriver.
B4M0227A
5) Take out DOJ outer race from shaft assembly.
6) Wipe off grease and take out balls.
CAUTION:
The grease is a special grease (grease for constant
velocity joint). Do not confuse with other greases.
NOTE:
Disassemble exercising care not to lose balls (6 pcs).


1Outer race


2Grease
NOTE:
Clean all parts as necessary.
31
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

B4M0774
3. FTJ (Free-ring Tripod Joint)
1) Place alignment marks on shaft and outer race.
B4M0775A
2) Remove FTJ boot band and boot.
CAUTION:
Be careful not to damage boot.
B4M0776
3) Remove circlip from FTJ outer race using screwdriver.
4) Remove FTJ outer race from shaft assembly.
5) Wipe off grease.
CAUTION:
The grease is a special grease. Do not confuse with
other greases.
B4M0777
6) Place alignment mark on free ring and trunnion.
7) Remove free ring from trunnion.
33
4-2SERVICE PROCEDURE
4. Front and Rear Drive Shafts

2) Installation is in reverse order of removal.
CAUTION:

Use new retainers and clinch them when installing
brake shoes to levers.

Ensure that parking lever moves smoothly.

Do not confuse left parking lever with right one.

Do not confuse left strut with right one.
G4M0414
NOTE:
Ensure that adjuster assembly is securely installed with
screw in the left side, facing vehicle front.
G4M0415
NOTE:
Ensure that shoe return spring is installed as shown in
Figure.
3) Adjust parking brakes.
CAUTION:
After replacing parking brake lining, be sure to drive
vehicle for“break-in”purposes.
(1) Drive the vehicle about 35 km/h (22 MPH).
(2) With the parking brake release button pushed in,
pull the parking brake lever gently, pulling with a force
of approximately 147 N (15 kg, 33 lb).
(3) Drive the vehicle for about 200 m (0.12 mile) in this
condition.
(4) Wait 5 to 10 minutes for the parking brake to cool
down. Repeat this procedure once more.
(5) After breaking-in, re-adjust parking brakes.
46
4-4SERVICE PROCEDURE
4. Parking Brake (Rear Disc Brake)

G4M0462
3. CHECKING THE HYDRAULIC UNIT WITH BRAKE
TESTER
1) In the case of AWD vehicles, install a spare fuse with
the FWD connector in the engine compartment to simulate
FWD vehicles.
B4M0082A
2) Connect diagnosis terminals to 3 terminals (K) and 6
terminals (L) of the diagnosis connector beside driver seat
heater unit.
G4M0464
3) Set the front wheels or rear wheels on the brake tester
and set the select lever’s position at“neutral”.
4) Operate the brake tester.
5) Perform sequence control.
(1) Turn ignition switch ON.
(2) The ABS warning light comes on.
(3) Depress the brake pedal within 0.5 seconds after
the warning light goes out so that the brake tester reg-
isters a pressure equal to the initial value.
CAUTION:
Do not depress the clutch pedal.
NOTE:
The engine must not be operating.
6) Hydraulic unit begins to work; and check the following
working sequence.
(1) The left front wheel performs decompression,
holding, and compression in sequence, and subse-
quently the right front wheel repeats the cycle.
(2) Simultaneously both right and left rear wheel per-
form decompression, holding, and compression in
sequence.
77
4-4SERVICE PROCEDURE
15. Hydraulic Unit for ABS System (Except ABS 5.3 Type)

7) Read values indicated on the brake tester and check if
the fluctuation of values, when decompressed and
compressed, meet the standard values.
Initial value When decompressed When compressed
Front wheel 1,961 N (200 kg, 441 lb) 245 N (25 kg, 55 lb) 1,961 N (200 kg, 441 lb)
Rear wheel 686 N (70 kg, 154 lb) 245 N (25 kg, 55 lb) 686 N (70 kg, 154 lb)

In case of hydraulic unit plunger piston malfunction:
Initial value When decompressed When compressed
Rear right wheel 686 N (70 kg, 154 lb) 245 N (25 kg, 55 lb) 686 N (70 kg, 154 lb)
Rear left wheel 686 N (70 kg, 154 lb) 686 N (70 kg, 154 lb) 686 N (70 kg, 154 lb)
8) After checking, also check if any irregular brake pedal
tightness is felt.
9) In case of AWD vehicles, remove the spare fuse from
the FWD connector in the engine compartment to return to
the original AWD state.
C: SEQUENCE CONTROL
Under the sequence control, after the hydraulic unit sole-
noid valve is driven, the operation of the hydraulic unit can
be checked by means of the brake tester or pressure
gauge.
B4M0082A
1. OPERATIONAL GUIDELINES OF THE SEQUENCE
CONTROL
1) Connect diagnosis terminals to 3 terminals (K) and 6
terminals (L) of the diagnosis connector beside driver seat
heater unit.
2) Set the speed of all wheels at 4 km/h (2 MPH) or less.
3) Within 0.5 seconds after the ABS warning lamp goes
out, immediately after the ignition switch is turned to on,
depress the brake pedal and hold.
CAUTION:
Do not depress the clutch pedal.
NOTE:

When the ignition switch is set to on, the brake pedal
must not be depressed.

Engine must not operate.
78
4-4SERVICE PROCEDURE
15. Hydraulic Unit for ABS System (Except ABS 5.3 Type)

G4M0462
2. CHECKING THE HYDRAULIC UNIT ABS
OPERATION WITH BRAKE TESTER
1) In the case of AWD AT vehicles, install a spare fuse with
the FWD connector in the engine compartment to simulate
FWD vehicles.
2) Prepare for operating ABS sequence control. 4-4 [W22D1] or 4-4 [W22D2].>
G4M0464
3) Set the front wheels or rear wheels on the brake tester
and set the select lever’s position at“neutral”.
4) Operate the brake tester.
5) Perform ABS sequence control. step 1 or 4-4 [W22D2] step 1.>
6) Hydraulic unit begins to work; and check the following
working sequence.
(1) The FL wheel performs decompression, holding,
and compression in sequence, and subsequently the
FR wheel repeats the cycle.
(2) The RR wheel performs decompression, holding,
and compression in sequence, and subsequently the
RL wheel repeats the cycle.
7) Read values indicated on the brake tester and check if
the fluctuation of values, when decompressed and
compressed, meet the standard values.
Unit: N (kg, lb)
Initial value When decompressed When compressed
Front wheel 981 (100, 221) 490 (50, 110) or less 981 (100, 221) or more
Rear wheel 981 (100, 221) 490 (50, 110) or less 981 (100, 221) or more
8) After checking, also check if any irregular brake pedal
tightness is felt.
11 3
4-4SERVICE PROCEDURE
22. Hydraulic Unit for ABS System (ABS 5.3 Type)

1. Air Conditioning System
1. LHD MODEL
B4M0757A

1Receiver drier bracket


2Pipe (Receiver drier—Evaporator module)


3Receiver drier


4Evaporator unit


5Hose (Low-pressure)


6A/C relay


7Fuse


8Hose (High-pressure)


9Compressor


10Condenser


11Pipe (Condenser—Receiver drier)
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
T2: 15±5 (1.5±0.5, 10.8±3.6)
T3: 15±3 (1.5±0.3, 10.8±2.2)
T4: 25±5 (2.5±0.5, 18.1±3.6)
3
4-7COMPONENT PARTS
1. Air Conditioning System