diff SUBARU LEGACY 1999 Service Repair Manual

6) Remove bolts securing crossmember to vehicle
body, and remove crossmember.
G4M0545
7) Scribe an alignment mark on rear lateral link
cam bolt and crossmember.
8) Remove four bolts securing front and rear lat-
eral links to crossmember by loosening nuts.
B: INSPECTION
Check removed parts for damage and cracks, and
correct or replace if defective.
C: INSTALLATION
1) Install in reverse order of removal.
2) Install rear differential.
CAUTION:
Always tighten rubber bushing when wheels
are in full contact with the ground and vehicle
is at curb weight condition.
NOTE:
Check wheel alignment and adjust if necessary.
37
[W10C0]4-1SERVICE PROCEDURE
10. Rear Crossmember

CAUTION:
Be sure to press hub bolts until their seating
surfaces contact the hub.
NOTE:
Use 12 mm (0.47 in) dia. holes in HUB STAND to
prevent bolts from tilting.
3) Remove foreign particles (dust, rust, etc.) from
mating surfaces of hub and tone wheel, and install
tone wheel to hub (only vehicle equipped with
ABS).
CAUTION:
IBe careful not to damage tone wheel teeth.
IEnsure tone wheel closely contacts hub.
G4M0231
4) Clean dust or foreign particles from inside the
housing.
5) Using ST1 and ST2, press a new bearing into
place.
ST1 927400000 HOUSING STAND
ST2 927100000 BEARING REMOVER
CAUTION:
IAlways press outer race when installing
bearing.
IBe careful not to remove plastic lock from
inner race when installing bearing.
ICharge bearing with new grease when outer
race is not removed.
G4M0232
6) Install snap ring in its groove.
NOTE:
Make sure to install it firmly to groove.7) Using ST1 and ST2, press outer oil seal until it
contacts the bottom of housing.
ST1 927410000 OIL SEAL INSTALLER
ST2 927400000 HOUSING STAND
G4M0233
8) Using ST1 and ST2, press inner oil seal until it
contacts circlip.
ST1 927410000 OIL SEAL INSTALLER
ST2 927400000 HOUSING STAND
G4M0234
9) Invert ST and housing.
ST 927400000 HOUSING STAND
10) Apply sufficient grease to oil seal lip.
Specified grease:
SHELL 6459N
CAUTION:
IIf specified grease is not available, remove
bearing grease and apply Auto Rex A instead.
IDo not mix different types of grease.
11) Install disc cover to housing the three bolts.
Tightening torque:
14
±4 N´m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
12
4-2[W1D0]SERVICE PROCEDURE
1. Front Axle

CAUTION:
Be sure to loosen and retighten axle nut after
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
3) Unlock axle nut.
4) Remove axle nut using a socket wrench.
5) Return parking brake lever and loosen adjust-
ing nut.
B4M0050A
6) Remove brake drum from hub.
7) If it is difficult to remove brake drum, remove
adjusting hole cover from back plate, and then turn
adjusting screw using a slot-type screwdriver until
brake shoe separates from the drum.
G4M0242
NOTE:
If brake drum is difficult to remove, drive it out by
installing an 8-mm bolt into bolt hole in brake drum.
G4M0243
8) Using a flare-nut wrench, disconnect brake pipe
from wheel cylinder.
CAUTION:
Cover open end of wheel cylinder to prevent
entry of foreign particles.
G4M0244
9) Disconnect parking brake cable end.
G4M0241
10) Remove bolts which secure trailing link
assembly to rear housing.
CAUTION:
Discard old self-locking nut. Replace with a
new one.
G4M0246
16
4-2[W2A2]SERVICE PROCEDURE
2. Rear Axle

3) Clean housing interior completely. Using ST1
and ST2, press bearing into housing.
ST1 927430000 HOUSING STAND
ST2 927440000 BEARING REMOVER
CAUTION:
IAlways press outer race when installing
bearing.
IBe careful not to remove plastic lock from
inner race when installing bearing.
ICharge bearing with new grease when outer
race is not removed.
G4M0257
4) Install snap ring.
CAUTION:
Ensure snap ring fits in groove properly.
G4M0251
5) Using ST1 and ST2, press outer oil seal until it
comes in contact with snap ring.
ST1 927430000 HOUSING STAND
ST2 927460000 OIL SEAL INSTALLER
G4M0258
6) Invert both ST1 and housing.
7) Using ST2, press inner oil seal into housing
until it touches bottom.
ST1 927430000 HOUSING STAND
ST2 927460000 OIL SEAL INSTALLER
G4M0259
8) Using ST1 and ST2, press sub seal into place.
ST1 927430000 HOUSING STAND
ST2 927460000 OIL SEAL INSTALLER
G4M0260
9) Apply sufficient grease to oil seal lip.
Specified grease:
SHELL 6459N
CAUTION:
IIf specified grease is not available, remove
bearing grease and apply Auto Rex A instead.
IDo not mix different types of grease.
10) Install back plate to rear housing.
Tightening torque:
52
±6 N´m (5.3±0.6 kg-m, 38.3±4.3 ft-lb)
G4M0261
19
[W2D0]4-2SERVICE PROCEDURE
2. Rear Axle

3. Front and Rear Drive Shafts
A: REMOVAL
1. FRONT DRIVE SHAFT
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands
(rigid racks), and remove front wheel cap and
wheels.
3) Unlock axle nut.
4) While depressing brake pedal, remove axle nut
using a socket wrench.
CAUTION:
Be sure to loosen and retighten axle nut after
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
5) Disconnect stabilizer link from transverse link.
6) Disconnect transverse link from housing.
7) Remove spring pin which secures transmission
spindle to DOJ/SFJ.
CAUTION:
Use a new spring pin.
G4M0279
8) Remove front drive shaft assembly. If it is hard
to remove, use ST1 and ST2.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
IBe careful not to damage oil seal lip when
removing front drive shaft.
IWhen front drive shaft is to be replaced, also
replace inner oil seal.
G4M0216
2. REAR DRIVE SHAFT
1) Disconnect ground cable from battery.
2) Lift-up vehicle, and remove rear wheel cap and
wheels.
CAUTION:
Be sure to loosen and retighten axle nut after
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
3) Unlock axle nut.
4) Loosen axle nut using a socket wrench.
CAUTION:
Do not remove axle nut.
5) Remove ABS sensor clamps and parking brake
cable bracket.
6) Remove bolts which secure lateral link assem-
bly to rear housing.
CAUTION:
Discard old self-locking nut. Replace with a
new one.
7) Remove bolts which secure trailing link assem-
bly to rear housing.
CAUTION:
Discard old self-locking nut. Replace with a
new one.
8) Remove crossmember reinforcement lower
from crossmember (4 door model only).
9) Remove DOJ from rear differential using ST.
(Except 2200 cc AT vehicles)
ST 28099PA100 DRIVE SHAFT REMOVER
CAUTION:
Do not remove circlip attached to inside of dif-
ferential.
G4M0994
22
4-2[W3A1]SERVICE PROCEDURE
3. Front and Rear Drive Shafts

CAUTION:
Be careful not to damage side bearing retainer.
Always use bolt as shown in figure, as support-
ing point for ST during removal.
ST 28099PA100 DRIVE SHAFT REMOVER
G4M0995
10) Remove DOJ from rear differential using tire
lever. (2200 cc AT vehicles)
NOTE:
The side spline shaft circlip comes out together
with the shaft.
G3M0257
CAUTION:
When removing the DOJ from the rear
differential, fit tire lever to the bolt as shown in
figure so as not to damage the axle shaft
holder.
G3M0045
11) 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:
IBe careful not to damage oil seal lip when
removing rear drive shaft.
IWhen rear drive shaft is to be replaced, also
replace inner oil seal with a new one.
G4M0247
B: DISASSEMBLY
1. EXCEPT AWD AT FRONT DRIVE SHAFT
1) Remove both DOJ boot bands.
2) Loosen band by means of screwdriver or pliers
taking care to not damage the boot.
G4M0281
3) Remove the larger end of DOJ boot from DOJ
outer race.
4) Pry and remove round circlip located at the
neck of DOJ outer race with a screwdriver.
G4M0282
23
[W3B1]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

E: INSTALLATION
1. FRONT DRIVE SHAFT
1) Insert BJ into hub splines.
CAUTION:
Be careful not to damage inner oil seal lip.
2) Using ST1 and ST2, pull drive shaft into place.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER
CAUTION:
Do not hammer drive shaft when installing it.
G4M0291
3) Tighten axle nut temporarily.
4) Install DOJ/SFJ on transmission spindle and
drive spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
5) Connect transverse link to housing.
Tightening torque (self-locking nut):
49
±10 N´m (5.0±1.0 kg-m, 36±7 ft-lb)
CAUTION:
Use a new self-locking nut.
6) Install stabilizer bracket.
7) While depressing brake pedal, tighten axle nut
to the specified torque.
Tightening torque:
186
±20 N´m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
IUse a new axle nut.
IAlways tighten axle nut before installing
wheel on vehicle. If wheel is installed andcomes in contact with ground when axle nut is
loose, wheel bearings may be damaged.
IBe sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
8) After tightening axle nut, lock it securely.
2. REAR DRIVE SHAFT
1) Insert BJ into rear housing splines.
CAUTION:
Be careful not to damage inner oil seal lip.
2) Using ST1 and ST2, pull drive shaft into place.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER
CAUTION:
Do not hammer drive shaft when installing it.
G4M0293
3) Tighten axle nut temporarily.
4) Replace circlips from DOJ spline with new one.
(2200 cc AT vehicles only)
5) Using ST, install DOJ into differential.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
B4M0549A
34
4-2[W3E1]SERVICE PROCEDURE
3. Front and Rear Drive Shafts

6) Insert DOJ spline end into bore of side oil seal,
and remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil
seal.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
B4M0550A
7) Align DOJ and differential splines.
8) Push housing to insert DOJ into differential.
NOTE:
Make sure DOJ is inserted properly.
G3M0050
9) Connect crossmember reinforcement lower to
crossmember (4 door model only).
10) Connect rear housing assembly to trailing link
assembly, and tighten self-locking nut.
Tightening torque:
11 3
±15 N´m (11.5±1.5 kg-m, 83±11 ft-lb)
11) Connect rear housing assembly to lateral link
assembly, and tighten self-locking nut.
Tightening torque:
137
±20 N´m (14±2 kg-m, 101±14 ft-lb)
12) Install stabilizer bracket.
13) While depressing brake pedal, tighten axle nut
using a socket wrench.
Tightening torque:
186
±20 N´m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
IUse a new axle nut.
IAlways 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.
IBe sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
14) After tightening axle nut, lock it securely.
35
[W3E2]4-2SERVICE PROCEDURE
3. Front and Rear Drive Shafts

4. Replacement of Front SFJ,
DOJ and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands
(rigid racks), and remove front wheel cap and
wheels.
NOTE:
Do not remove axle nut.
3) Remove stabilizer link.
4) Disconnect transverse link from housing.
5) Remove spring pin which secures transmission
spindle to DOJ/SFJ.
CAUTION:
Use a new spring pin.
G4M0279
6) Remove SFJ, DOJ and BJ boots from drive
shaft. or [W3B2].>
B: INSTALLATION
1) Install SFJ, DOJ and BJ boots to drive shaft.
or
2) Install DOJ/SFJ on transmission spindle and
drive spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
3) Connect transverse link to housing.
4) Install stabilizer link.
5. Replacement of Rear DOJ
and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Lift-up vehicle, and remove rear wheel cap and
wheels.
NOTE:
Axle nut need not be removed.
3) Remove ABS sensor clamps and parking brake
cable bracket.
4) Disconnect stabilizer link from lateral link.
5) Remove bolts which secure lateral link assem-
bly to rear housing.
6) Remove bolts which secure trailing link assem-
bly to rear housing.
7) Remove crossmember reinforcement lower
from crossmember (4 door model only).
8) Remove DOJ from rear differential using ST.
(Except 2200 cc AT vehicles)
ST 28099PA100 DRIVE SHAFT REMOVER
CAUTION:
Do not remove circlip attached to inside of dif-
ferential.
G4M0994
CAUTION:
Be careful not to damage side bearing retainer.
Always use bolt as shown in figure, as support-
ing point for ST during removal.
ST 28099PA100 DRIVE SHAFT REMOVER
G4M0995
36
4-2[W4A0]SERVICE PROCEDURE
4. Replacement of Front SFJ, DOJ and BJ Boots

4. Replacement of Front SFJ,
DOJ and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands
(rigid racks), and remove front wheel cap and
wheels.
NOTE:
Do not remove axle nut.
3) Remove stabilizer link.
4) Disconnect transverse link from housing.
5) Remove spring pin which secures transmission
spindle to DOJ/SFJ.
CAUTION:
Use a new spring pin.
G4M0279
6) Remove SFJ, DOJ and BJ boots from drive
shaft. or [W3B2].>
B: INSTALLATION
1) Install SFJ, DOJ and BJ boots to drive shaft.
or
2) Install DOJ/SFJ on transmission spindle and
drive spring pin into place.
CAUTION:
Always use a new spring pin.
G4M0279
3) Connect transverse link to housing.
4) Install stabilizer link.
5. Replacement of Rear DOJ
and BJ Boots
A: REMOVAL
1) Disconnect ground cable from battery.
2) Lift-up vehicle, and remove rear wheel cap and
wheels.
NOTE:
Axle nut need not be removed.
3) Remove ABS sensor clamps and parking brake
cable bracket.
4) Disconnect stabilizer link from lateral link.
5) Remove bolts which secure lateral link assem-
bly to rear housing.
6) Remove bolts which secure trailing link assem-
bly to rear housing.
7) Remove crossmember reinforcement lower
from crossmember (4 door model only).
8) Remove DOJ from rear differential using ST.
(Except 2200 cc AT vehicles)
ST 28099PA100 DRIVE SHAFT REMOVER
CAUTION:
Do not remove circlip attached to inside of dif-
ferential.
G4M0994
CAUTION:
Be careful not to damage side bearing retainer.
Always use bolt as shown in figure, as support-
ing point for ST during removal.
ST 28099PA100 DRIVE SHAFT REMOVER
G4M0995
36
4-2[W4A0]SERVICE PROCEDURE
4. Replacement of Front SFJ, DOJ and BJ Boots