SUBARU LEGACY 1999 Service Repair Manual

MEMO:
50
3-4SERVICE PROCEDURE

1. Propeller Shaft
NOTE:
Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper
wheel alignment, etc.
Symptom Possible cause Remedy
1. Vibration of propeller shaft
NOTE:
Vibration is caused by propeller
shaft during operation and is trans-
ferred to vehicle body. Generally
vibration increases in proportion to
vehicle speed.(1) Worn or damaged universal joint. Replace.
(2) Unbalanced propeller shaft due to bend or dent. Replace.
(3) Loose installation of propeller shaft. Retighten.
(4) Worn or damaged center bearing and damaged
center mounting rubber.Replace.
2. Tapping when starting and
noise while cruising, caused by
propeller shaft.(1) Worn or damaged universal joint. Replace.
(2) Worn spline of sleeve yoke. Replace.
(3) Loose installation of propeller shaft. Retighten.
(4) Loose installation of joint. Replace.
(5) Worn or damaged center bearing and damaged
center mounting rubber.Replace.
51
[K100]3-4DIAGNOSTICS
1. Propeller Shaft

2. Rear Differential
Symptom Possible cause Remedy
1. Oil leakage(1) Worn, scratched, or incorrectly seated front or
side oil seal. Scored, battered, or excessively worn
sliding surface of companion flange.Repair or replace.
(2) Clogged or damaged air breather. Clean, repair or replace.
(3) Loose bolts on differential spindle or side
retainer, or incorrectly fitted O-ring.Tighten bolts to specified torque.
Replace O-ring.
(4) Loose rear cover attaching bolts or damaged
gasket.Tighten bolts to specified torque.
Replace gasket and apply liquid
packing.
(5) Loose oil filler or drain plug. Retighten and apply liquid packing.
(6) Wear, damage or incorrectly fitting for spindle,
side retainer and oil seal.Repair or replace.
2. Seizure
NOTE:
Seized or damaged parts should
be replaced, and also other parts
should be thoroughly checked for
any defect and should be repaired
or replaced as required.(1) Insufficient backlash for hypoid gear. Readjust or replace.
(2) Excessive preload for side, rear, or front bearing. Readjust or replace.
(3) Insufficient or improper oil used. Replace seized part and fill with
specified oil to specified level.
3. Damage
NOTE:
Damaged parts should be
replaced, and also other parts
should be thoroughly checked for
any defect and should be repaired
or replaced as required.(1) Improper backlash for hypoid gear. Replace.
(2) Insufficient or excessive preload for side, rear, or
front bearing.Readjust or replace.
(3) Excessive backlash for differential gear. Replace gear or thrust washer.
(4) Loose bolts and nuts such as crown gear bolt. Retighten.
(5) Damage due to overloading. Replace.
4. Noises when starting or shift-
ing gears
NOTE:
Noises may be caused by differen-
tial assembly, universal joint, wheel
bearing, etc. Find out what is actu-
ally making noise before disassem-
bly.(1) Excessive backlash for hypoid gear. Readjust.
(2) Excessive backlash for differential gear. Replace gear or thrust washer.
(3) Insufficient preload for front or rear bearing. Readjust.
(4) Loose drive pinion nut. Tighten to specified torque.
(5) Loose bolts and nuts such as side bearing
retainer attaching bolt.Tighten to specified torque.
5. Noises when cornering(1) Damaged differential gear. Replace.
(2) Excessive wear or damage of thrust washer. Replace.
(3) Broken pinion mate shaft. Replace.
(4) Seized or damaged side bearing. Replace.
6. Gear noises
NOTE:
Since noises from engine, muffler,
transmission, propeller shaft, wheel
bearings, tires, and body are
sometimes mistaken for noises
from differential assembly, be care-
ful in checking them. Inspection
methods to locate noises include
coasting, accelerating, cruising,
and jacking-up all four wheels.
Perform these inspections accord-
ing to condition of trouble. When
listening to noises, shift gears into
four wheel drive and fourth speed
position, trying to pick up only dif-
ferential noise.(1) Improper tooth contact of hypoid gear. Readjust or replace hypoid gear
set.
(2) Improper backlash for hypoid gear. Readjust.
(3) Scored or chipped teeth of hypoid gear. Replace hypoid gear set.
(4) Seized hypoid gear. Replace hypoid gear set.
(5) Improper preload for front or rear bearings. Readjust.
(6) Seized, scored, or chipped front or rear bearing. Replace.
(7) Seized, scored, or chipped side bearing. Replace.
(8) Vibrating differential carrier. Replace.
52
3-4[K200]DIAGNOSTICS
2. Rear Differential

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)
SUS & OUTBACK2200 cc 20 (0.79) 18 (0.71)
2500 cc 20 (0.79) 18 (0.71)
2
4-1[S100]SPECIFICATIONS AND SERVICE DATA
1. Stabilizer

2. Wheel Alignment
Sedan Wagon SUS & OUTBACK
AWD AWD AWD
FrontCamber
(tolerance:±0É30¢)þ0É05¢þ0É05¢0É20¢
Caster (tolerance:±1É) 3É05¢3É05¢2É50¢
Toe-in mm (in) 0±3(0±0.12) Total toe angle: 0ɱ20¢
Kingpin angle (tolerance:±1É) 14É15¢14É15¢13É30¢
Wheel arch height
[tolerance:
+12/þ24mm (+0.47/þ0.94in)] mm (in)385 (15.16) 385 (15.16) 420 (16.54)
RearCamber (tolerance:±0É45¢) þ1É þ0É55¢þ0É35¢
Toe-in mm (in) 0±3(0±0.12) Total toe angle: 0ɱ20¢
Wheel arch height
[tolerance:
+12/þ24mm (+0.47/þ0.94in)] mm (in)369 (14.53) 379 (14.92) 419 (16.50)
Thrust angle 0ɱ20¢
NOTE:
IFront 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.
IThe other items indicated in the specification
table cannot be adjusted. If the other items
exceeds specifications, check suspension parts
and joint portions of body suspension parts for
deformities; and replace with new ones as
required.
B4M0182A
3
[S200]4-1SPECIFICATIONS AND SERVICE DATA
2. Wheel Alignment

1. Front Suspension
B4M1148B
(1) Front crossmember
(2) Bolt ASSY
(3) Housing
(4) Washer
(5) Stopper rubber (Rear)
(6) Rear bushing
(7) Stopper rubber (Front)
(8) Ball joint
(9) Transverse link
(10) Cotter pin
(11) Front bushing
(12) Stabilizer link
(13) Clamp (2200 cc model)
(14) Bushing (2200 cc model)
(15) Stabilizer
(16) Jack-up plate (Except 2500 cc
MT model)(17) Dust seal
(18) Strut mount
(19) Spacer
(20) Upper spring seat
(21) Rubber seat
(22) Dust cover
(23) Helper
(24) Coil spring
(25) Damper strut
(26) Adjusting bolt
(27) Castle nut
(28) Self-locking nut
(29) Adapter front crossmember
(SUS & OUTBACK model)
(30) Clip (SUS & OUTBACK model)
(31) Bushing (2500 cc model)
(32) Clamp (2500 cc model)(33) Dynamic damper (2500 cc MT
model)
(34) Jack-up plate (2500 cc MT
model)
4
4-1[C100]COMPONENT PARTS
1. Front Suspension

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)
5
[C100]4-1COMPONENT PARTS
1. Front Suspension

2. Rear Suspension
B4M0766B
(1) Stabilizer
(2) Stabilizer bracket
(3) Stabilizer bushing
(4) Clamp
(5) Floating bushing
(6) Stopper
(7) Stabilizer link
(8) Rear lateral link
(9) Bushing (C)
(10) Bushing (A)
(11) Front lateral link
(12) Bushing (B)
(13) Trailing link rear bushing
(14) Trailing link
(15) Trailing link front bushing
(16) Trailing link bracket(17) Cap (Protection)
(18) Washer
(19) Rear crossmember
(20) Strut mount cap
(21) Strut mount
(22) Rubber seat upper
(23) Dust cover
(24) Coil spring
(25) Helper
(26) Rubber seat lower
(27) Damper strut
(28) Self-locking nut
(29) Crossmember reinforcement
lower (Sedan model and except
SUS model)(30) Adapter rear crossmember (SUS
& 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)
T7:11 3±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/þ10(20.0+4.0/þ1.0, 145+29/þ7)
6
4-1[C200]COMPONENT PARTS
2. Rear Suspension

1. On-car Services
A: WHEEL ALIGNMENT
PROCEDURES
Check, adjust and/or measure wheel alignment in
accordance with procedures indicated in figure:
B4M1088A
7
[W1A0]4-1SERVICE PROCEDURE
1. On-car Services

B: INSPECTION AND ADJUSTMENT
1. WHEEL ARCH HEIGHT (FRONT AND
REAR)
1) Adjust tire pressure to specifications.
2) Set vehicle under ªcurb weightº conditions.
(Empty luggage 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 ªAº 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
Sedan 385
+12/þ24(15.16+0.47/þ0.94) 369+12/þ24(14.53+0.47/þ0.94)
Wagon 385+12/þ24(15.16+0.47/þ0.94) 379+12/þ24(14.92+0.47/þ0.94)
SUS & OUTBACK 420+12/þ24(16.54+0.47/þ0.94) 419+12/þ24(16.50+0.47/þ0.94)
8
4-1[W1B1]SERVICE PROCEDURE
1. On-car Services