flat tire 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

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

1. Suspension
1. IMPROPER VEHICLE POSTURE OR IMPROPER
WHEEL ARCH HEIGHT
Possible causes Countermeasures
(1) Permanent distortion or breakage of coil spring Replace.
(2) Unsmooth operation of damper strut Replace.
(3) Installation of wrong strut Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.
2. POOR RIDE COMFORT
1) Large rebound shock
2) Rocking of vehicle continues too long after running over
bump and/or hump.
3) Large shock in bumping
Possible causes Countermeasures
(1) Breakage of coil spring Replace.
(2) Over-inflation pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace coil springs with new ones.
(4) Fault in operation of damper strut Replace.
(5) Damage or deformation of strut mount Replace.
(6) Unsuitability of maximum and/or minimum length of
damper strutReplace with proper parts.
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly Replace.
(9) Oil leakage of damper strut Replace.
3. NOISE
Possible causes Countermeasures
(1) Wear or damage of damper strut component parts Replace.
(2) Loosening of suspension link installing bolt and/or nut Retighten to the specified torque.
(3) Deformation or loss of bushing Replace.
(4) Unsuitability of maximum and/or minimum length of
damper strutReplace with proper parts.
(5) Breakage of coil spring Replace.
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.
47
4-1DIAGNOSTICS
1. Suspension

G4M0208
1. Wheels and Axles
A: SPECIFICATIONS
1. TIRE AND WHEEL SIZE
Tire size Rim sizeRim offset
mm (in)P.C.D.
mm (in)
Except OUTBACK modelFront and RearP185/70R14
87S14×5 1/2JJ 55 (2.17)
100 (3.94)
dia. P195/60R15
87H15 x 6JJ 55 (2.17)
T-type tireT125/70D15 15 x 4T 53 (2.09)
T135/70D16 16 x 4T 50 (1.97)
OUTBACK modelFront and RearP205/70R15
95S15 x 6JJ 55 (2.17)
T-type tire T135/80D16 16 x 4T 50 (1.97)
NOTE:“T-type”tire for temporary use is supplied as a spare tire.
2. TIRE INFLATION PRESSURE
Tire sizeTire inflation pressure kPa (kg/cm
2, psi)
Light load Full load Trailler towing
Except OUTBACK
modelFront and RearP185/70R14 87S
P195/60R15 87HFt: 220 (2.2, 32)
Rr: 210 (2.1, 30)—
T-type tireT125/70D15
T135/70D16420 (4.2, 60)
OUTBACK modelFront and Rear P205/70R15 95SFt: 200 (2.0, 29)
Rr: 190 (1.9, 28)Ft: 200 (2.0, 2.9)
Rr: 220 (2.2, 32)
T-type tire T135/80D16 420 (4.2, 60)
2
4-2SPECIFICATIONS AND SERVICE DATA
1. Wheels and Axles

G4M0301
12. Tire Rotation
If tires are maintained at the same positions for a long
period of time, uneven wear results. Therefore, they should
be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating tires, replace unevenly worn or dam-
aged tires with new ones.
13.“T-type”Tire
“T-type”tire for temporary use is prepared as a spare tire.
CAUTION:
Keep the inflation pressure at 420 kPa (4.2 kg/cm
2,
60 psi) at all times.
When the wear indicator appears on the tread
surface, replace the tire with a new one.
Do not use a tire chain with the“T-type”tire.
Because of the smaller tire size, a tire chain will not fit
properly and will result in damage to the vehicle and
the tire.
Do not drive at a speed greater than 80 km/h (50
MPH).
Drive as slowly as possible and avoid passing over
bumps.
Replace with a conventional tire as soon as possible
since this“T-type”tire is only for temporary use.
52
4-2SERVICE PROCEDURE
12. Tire Rotation - 13.“T-type”Tire

G4M0301
12. Tire Rotation
If tires are maintained at the same positions for a long
period of time, uneven wear results. Therefore, they should
be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating tires, replace unevenly worn or dam-
aged tires with new ones.
13.“T-type”Tire
“T-type”tire for temporary use is prepared as a spare tire.
CAUTION:
Keep the inflation pressure at 420 kPa (4.2 kg/cm
2,
60 psi) at all times.
When the wear indicator appears on the tread
surface, replace the tire with a new one.
Do not use a tire chain with the“T-type”tire.
Because of the smaller tire size, a tire chain will not fit
properly and will result in damage to the vehicle and
the tire.
Do not drive at a speed greater than 80 km/h (50
MPH).
Drive as slowly as possible and avoid passing over
bumps.
Replace with a conventional tire as soon as possible
since this“T-type”tire is only for temporary use.
52
4-2SERVICE PROCEDURE
12. Tire Rotation - 13.“T-type”Tire

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.








83
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.
124
4-4DIAGNOSTICS
1. Entire Brake System

2. Hill Holder
Trouble and possible cause Corrective action
1. Counterforce of clutch pedal is too strong.
(1) PHV cable is damaged or does not operate properly. Repair or replace.
(2) Lever of PHV is defective. Replace entire PHV assembly.
(3) Clutch system is anomalous. Refer to“Clutch and pedal cable system”.
2. Vehicle does not stop on uphill road of 3°or higher inclination.
(1) Front side of vehicle is lowered. Refer to“Suspension”.
(2) PHV cable is broken. Replace.
(3) Play of clutch is excessive. Adjust.
(4) PHV cable is elongated. Adjust.
(5) Sealing of PHV is poor. Replace entire PHV assembly.
3. Shock is felt when starting.
(1) Poor adjustment of starting performance: Adjust.
(2) When depressing the brake pedal strongly:(The stronger brake pedal depressing force, the later hill holder
releases.)
(3) When starting on flat road after stopping reverse movement: (Because hill holder is activated.)
4. Vehicle slips down when starting.
(1) PHV cable is elongated. Adjust.
(2) Clutch facing is worn out. Adjust or replace.
(3) Bracket (cable) or stay (PHV) is deformed. Repair or replace.
5. Vehicle cannot start after stoppage.
(1) Return spring is fatigued or broken. Replace.
(2) PHV lever won’t return. Replace entire PHV assembly.
(3) When intentionally depressing brake pedal strongly:[When the brake pedal is depressed by a force of 1,177 N (120
kg, 265 lb) or more.]
6. Abnormal sound is generated upon releasing brake pedal when stopping.
(1) Rotor and pad matched with each other due to inadequate
depressing force to brake pedal.(Abnormal sound is not generated when depressing brake pedal a
little stronger.)
7. Abnormal sound is generated when operating clutch pedal.
(1) Grease is inadequate for the hook of return spring and slid-
ing portion of PHV cable end.Apply grease.
(2) When releasing after maintaining high fluid pressure: (Flowing sound of fluid when releasing high fluid pressure.)
(3) Clutch system is anomalous. Refer to“Clutch and pedal cable system”.
CAUTION:

Description in parentheses is a characteristic of hill holder and does not indicate abnormality.
Depressing force required for clutch pedal equipped to hill holder specifications is 20 to 29 N (2 to 3 kg, 4 to 7 lb) larger than
the conventional specifications, which does not constitute abnormality.

When vehicle cannot travel (brake cannot be released) because return spring is broken, remove adjusting nut, disconnect
clutch and PHV, and then return PHV lever to release the brake. (Be sure to apply the parking brake before starting this opera-
tion.)

The hill holder may not be activated on a slope of an extremely small inclination.
126
4-4DIAGNOSTICS
2. Hill Holder

B6M0048
B: INSPECTION
1. IGNITION SWITCH (ON-CAR)
1) Remove instrument panel lower cover.
2) Remove lower column cover.
3) Unfasten holddown clip which secures harness, and
disconnect connector of ignition switch from body harness.
4) Turn ignition key to each position and check continuity
between terminals of ignition switch connector.
Terminal
Positiona-1 a-2 a-5 a-4
LOCK
ACC
ON
START
B6M0335A
4. Headlight
A: ADJUSTMENT
1. HEADLIGHT AIMING
1) Adjust the headlight aiming by turning the adjusting
screws.
CAUTION:
Before checking the headlight aiming, be sure of the
following:

Turn off the light before adjusting headlight aiming.
If the light is necessary to check aiming, do not turn on
for more than two minutes.

The area around the headlight has not sustained any
accident, damage or other type of deformation.

Vehicle is parked on level ground.

The inflation pressure of tires is correct.

Vehicle’s gas tank is fully charged.

Bounce the vehicle several times to normalize the
suspension.

Make certain that someone is seated in the driver’s
seat.
NOTE:
Adjust vertical aim first, then horizontal aim.
8
6-2SERVICE PROCEDURE
3. Ignition Switch - 4. Headlight