SUBARU LEGACY 1999 Service Repair Manual

4. Front Strut
A: REMOVAL
B4M1085A
(1) Dust seal
(2) Strut mount
(3) Spacer
(4) Upper spring seat
(5) Rubber seat
(6) Dust cover(7) Helper
(8) Coil spring
(9) Damper strut
(10) Adjusting bolt
(11) Self-locking nutTightening torque: N´m (kg-m, ft-lb)
T1:
20±6 (2.0±0.6, 14.5±4.3)
T2:54±5 (5.5±0.5, 39.8±3.6)
T3:152±20 (15.5±2.0, 112±14)
1) Remove wheel.
2) Depress brake pedal and hold it down using a
wooden block etc.
3) Remove union bolts from caliper.
CAUTION:
Use brake hose cap to prevent brake fluid from
escaping.
G4M0503
4) Remove brake hose clamp and disconnect
brake hose from strut. Attach brake hose to body
using gum tape.
G4M0504
5) Scribe an alignment mark on the camber
adjusting bolt which secures strut to housing.
6) Remove bolt securing the ABS sensor harness.
(ABS equipped models.)
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4-1[W4A0]SERVICE PROCEDURE
4. Front Strut

7) Remove two bolts securing housing to strut.
CAUTION:
While holding head of adjusting bolt, loosen
self-locking nut.
8) Remove the three nuts securing strut mount to
body.
G4M0505
B: DISASSEMBLY
1) Using a coil spring compressor, compress coil
spring.
G4M0506
2) Using ST, remove self-locking nut.
ST 927760000 STRUT MOUNT SOCKET
G4M0507
3) Remove strut mount, upper spring seat and
rubber seat from strut.
4) Gradually decreasing compression force of
spring compressor, and remove coil spring.
5) Remove dust cover and helper.
C: INSPECTION
Check the disassembled parts for cracks, damage
and wear, and replace with new parts if defective.
1. DAMPER STRUT
1) Check for oil leakage.
2) Move the piston rod up and down to check its
operates smoothly without any binding.
3) Play of piston rod
IMeasure the play as follows:
Fix outer shell and fully extend the rod. Set a dial
gauge at the end of the rod: L [10 mm (0.39 in)],
then apply a force of W [20 N (2 kg, 4 lb)] to
threaded portion. With the force of 20 N (2 kg, 4 lb)
applied, read dial gauge indication: P
1. Apply a
force of 20 N (2 kg, 4 lb) in the opposite direction
of ªWº, then read dial gauge indication: P
2.
G4M0508
The free play is determined by the following equa-
tion:
Play = P1,P2
Limit of play:
Less than 0.8 mm (0.031 in)
If the play is greater, replace the strut with new
one.
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[W4C1]4-1SERVICE PROCEDURE
4. Front Strut

2. STRUT MOUNT
Check rubber part for wear, cracks and
deterioration, and replace it with new one if defec-
tive.
3. DUST COVER
If any cracks or damage are found, replace it with
new one.
4. COIL SPRING
When vehicle posture is uneven, although there
are no considerable reasons like tire puncture,
uneven loading, etc., check coil spring and spring
seats for cracks, deformation, etc., and replace it
with a new one if defective.
5. HELPER
Replace it with new one if cracked or damaged.
D: ASSEMBLY
1) Before installing coil spring, strut mount, etc.,
on the strut, check for the presence of air in the
dampening force generating mechanism of the
strut since air prevents proper dampening force
from being produced.
2) Checking for the presence of air
(1) Place the strut vertically with the piston rod
facing upward.
(2) Move the piston rod to the center of its
entire stroke.
(3) While holding the piston rod end with finger-
tips, move the rod up and down.
(4) If the piston rod moves at least 10 mm (0.39
in) in former step, purge air from the strut.
3) Air purging procedure
(1) Place the strut vertically with the piston rod
facing upward.
(2) Fully extend the piston rod.
(3) With the piston rod fully extended, place the
piston rod side down. The strut must stand ver-
tically.
(4) Fully contract the piston rod.
(5) Repeat 3 or 4 times from first step.
NOTE:
After completely purging air from the strut, be sure
to place the strut with the piston rod facing upward.
If it is laid down, check for entry of air in the strut
as outlined under ªChecking for the presence of
airº.4) Using a coil spring compressor, compress the
coil spring.
NOTE:
Make sure that the vertical installing direction of
coil spring is as shown in figure.
B4M0568A
5) Set the coil spring correctly so that its end face
fits well into the spring seat as shown.
G4M0510
6) Install helper and dust cover to the piston rod.
7) Pull the piston rod fully upward, and install rub-
ber seat and spring seat.
NOTE:
Ensure that upper spring seat is positioned with
ªOUTº mark facing outward.
G4M0511
8) Install strut mount to the piston rod, and tighten
the self-locking nut temporarily.
CAUTION:
Be sure to use a new self-locking nut.
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4-1[W4C2]SERVICE PROCEDURE
4. Front Strut

9) Using hexagon wrench to prevent strut rod from
turning, tighten self-locking nut with ST.
ST 927760000 STRUT MOUNT SOCKET
Tightening torque:
54
±5 N´m (5.5±0.5 kg-m, 39.8±3.6 ft-lb)
G4M0507
10) Loosen the coil spring carefully.
E: INSTALLATION
1) Install strut mount at upper side of strut to body
and tighten with nuts.
Tightening torque:
20
±6 N´m (2.0±0.6 kg-m, 14.5±4.3 ft-lb)
2) Connect housing to lower side of strut.
3) Position aligning mark on camber adjusting bolt
with aligning mark on lower side bracket of strut.
CAUTION:
IWhile holding head of adjusting bolt, tighten
self-locking nut.
IBe sure to use new self-locking nut.
Tightening torque:
152
±20 N´m (15.5±2.0 kg-m, 112±14 ft-lb)
4) Install ABS sensor harness to strut. (ABS
equipped models.)
Tightening torque:
152
±20N´m (15.5±2.0 kg-m, 112±14 ft-lb)
5) Install brake hose at lower side of strut with
clamp.
6) Install union bolts which secure brake caliper to
brake hose.
Tightening torque:
18
±3 N´m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
G4M0503
CAUTION:
Be sure to bleed air from brake system.
7) Install wheels.
NOTE:
Check wheel alignment and adjust if necessary.
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[W4E0]4-1SERVICE PROCEDURE
4. Front Strut

5. Front Stabilizer
A: REMOVAL
B4M1086A
(1) Front crossmember
(2) Transverse link
(3) Jack-up plate
(4) Stabilizer link
(5) Front stabilizer(6) Self-locking nutTightening torque:N´m (kg-m, ft-lb)
T1:
25±4 (2.5±0.4, 18.1±2.9)
T2:29±5 (3.0±0.5, 21.7±3.6)
T3:18±5 (1.8±0.5, 13.0±3.6)
T4:44±6 (4.5±0.6, 32.5±4.3)
1) Jack-up the front part of the vehicle, support it
with safety stand (rigid racks).
2) Remove bolts which secure stabilizer to cross-
member.
G4M0515
3) Remove bolts which secure stabilizer link to
front transverse link.
G4M0516
4) Remove jack-up plate from lower part of cross-
member.
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4-1[W5A0]SERVICE PROCEDURE
5. Front Stabilizer

B: INSPECTION
1) Check bushing for cracks, fatigue or damage.
2) Check stabilizer link for deformities, cracks, or
damage, and bushing for protrusions from the hole
of stabilizer link and its play.
C: INSTALLATION
1) To install, reverse the removal procedure.
NOTE:
IInstall bushing (on front crossmember side)
while aligning it with paint mark on stabilizer.
IEnsure that bushing and stabilizer have the
same identification colors when installing.
G4M0519
2) Always tighten rubber bushing location when
wheels are in full contact with the ground and
vehicle is at curb weight condition.
Tightening torque:
Jack-up plate to crossmember:
18
±5 N´m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
Stabilizer link to front transverse link:
29
±5 N´m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
Stabilizer to crossmember:
25
±4 N´m (2.5±0.4 kg-m, 18.1±2.9 ft-lb)
6. Front Crossmember
A: REMOVAL
1) Disconnect ground cable from battery.
2) Loosen front wheel nuts.
3) Lift-up vehicle, and remove front tires and
wheels.
4) Remove both stabilizer and jack-up plate.
G4M0520
5) Disconnect tie-rod end from housing.
6) Remove front exhaust pipe.
7) Remove front transverse link from front cross-
member and body.
G4M0521
8) Remove nuts attaching engine mount cushion
rubber to crossmember.
9) Remove self-locking nuts connecting steering
U/J and pinion shaft.
10) Lift engine by approx. 10 mm (0.39 in) by
using chain block.
11) Support crossmember with a jack, remove
nuts securing crossmember to body and lower
crossmember gradually along with steering gear-
box.
CAUTION:
When removing crossmember downward, be
careful that tie-rod end does not interfere with
DOJ boot.
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[W6A0]4-1SERVICE PROCEDURE
6. Front Crossmember

B: INSPECTION
1) Check bushing for cracks, fatigue or damage.
2) Check stabilizer link for deformities, cracks, or
damage, and bushing for protrusions from the hole
of stabilizer link and its play.
C: INSTALLATION
1) To install, reverse the removal procedure.
NOTE:
IInstall bushing (on front crossmember side)
while aligning it with paint mark on stabilizer.
IEnsure that bushing and stabilizer have the
same identification colors when installing.
G4M0519
2) Always tighten rubber bushing location when
wheels are in full contact with the ground and
vehicle is at curb weight condition.
Tightening torque:
Jack-up plate to crossmember:
18
±5 N´m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
Stabilizer link to front transverse link:
29
±5 N´m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
Stabilizer to crossmember:
25
±4 N´m (2.5±0.4 kg-m, 18.1±2.9 ft-lb)
6. Front Crossmember
A: REMOVAL
1) Disconnect ground cable from battery.
2) Loosen front wheel nuts.
3) Lift-up vehicle, and remove front tires and
wheels.
4) Remove both stabilizer and jack-up plate.
G4M0520
5) Disconnect tie-rod end from housing.
6) Remove front exhaust pipe.
7) Remove front transverse link from front cross-
member and body.
G4M0521
8) Remove nuts attaching engine mount cushion
rubber to crossmember.
9) Remove self-locking nuts connecting steering
U/J and pinion shaft.
10) Lift engine by approx. 10 mm (0.39 in) by
using chain block.
11) Support crossmember with a jack, remove
nuts securing crossmember to body and lower
crossmember gradually along with steering gear-
box.
CAUTION:
When removing crossmember downward, be
careful that tie-rod end does not interfere with
DOJ boot.
23
[W6A0]4-1SERVICE PROCEDURE
6. Front Crossmember

B: INSTALLATION
1) Installation is in the reverse order of removal
procedures.
CAUTION:
Always tighten rubber bushing when wheels
are in full contact with the ground and vehicle
is at curb weight condition.
Tightening torque:
Transverse link bushing to crossmember:
98
±15 N´m (10.0±1.5 kg-m, 72±11 ft-lb)
Stabilizer to bushing:
25
±4 N´m (2.5±0.4 kg-m, 18.1±2.9 ft-lb)
Tie-rod end to housing:
27.0
±2.5 N´m (2.75±0.25 kg-m, 19.9±1.8
ft-lb)
Front cushion rubber to crossmember:
69
±15 N´m (7.0±1.5 kg-m, 51±11 ft-lb)
Universal joint to pinion shaft:
24
±3 N´m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
Crossmember to body:
98
±15 N´m (10.0±1.5 kg-m, 72±11 ft-lb)
2) Purge air from power steering system.
NOTE:
Check wheel alignment and adjust if necessary.
24
4-1[W6B0]SERVICE PROCEDURE
6. Front Crossmember

7. Rear Trailing Link
A: REMOVAL
H4M1066C
(1) Trailing link
(2) Front bushing
(3) Rear bushing
(4) Bracket(5) Housing
(6) Self-locking nutTightening torque: N´m (kg-m, ft-lb)
T1:
98±20 (10.0±2.0, 72±14)
T2:11 3±15 (11.5±1.5, 83±11 )
1) Loosen rear wheel nuts.
2) Lift-up vehicle, support it with safety stands
(rigid racks) and remove rear wheels.
3) Remove both rear parking brake clamp and
ABS sensor harness. (ABS equipped models.)
4) Remove bolt which secure trailing link to trailing
link bracket.
B4M0570A
5) Remove bolt which secure trailing link to rear
housing.
25
[W7A0]4-1SERVICE PROCEDURE
7. Rear Trailing Link

B: DISASSEMBLY
1. FRONT BUSHING
Using ST, press front bushing out of place.
ST 927720000 INSTALLER & REMOVER SET
G4M0524
2. REAR BUSHING
1) Remove housing.
2) Using ST, press rear bushing out of place.
ST 927730000 INSTALLER & REMOVER SET
G4M0525
C: INSPECTION
Check trailing links for bends, corrosion or dam-
age.
D: ASSEMBLY
To assemble, reverse above disassembly proce-
dures.
1. FRONT BUSHING
Using ST, press bushing into trailing link.
ST 927720000 INSTALLER & REMOVER SET
CAUTION:
When installing bushing, turn ST plunger
upside down and press it until plunger end sur-
face contacts trailing link end surface.
B4M0226A
CAUTION:
Install front bushing in the proper direction, as
shown in figure.
G4M0924
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4-1[W7B1]SERVICE PROCEDURE
7. Rear Trailing Link