SUBARU LEGACY 1999 Service Repair Manual

1. Front Axle
A: EXCEPT AWD AT MODEL
H4M0999B
(1) Spring pin
(2) Baffle plate (DOJ)
(3) Outer race (DOJ)
(4) Snap ring
(5) Inner race (DOJ)
(6) Ball
(7) Cage
(8) Circlip
(9) Boot band(10) Boot (DOJ)
(11) Boot (BJ)
(12) BJ ASSY
(13) Baffle plate
(14) Oil seal (IN)
(15) Snap ring
(16) Bearing
(17) Housing
(18) Oil seal (OUT)(19) Tone wheel
(20) Hub bolt
(21) Hub
(22) Axle nut
Tightening torque: N´m (kg-m, ft-lb)
T1:
13±3 (1.3±0.3, 9.4±2.2)
T2:186±20 (19±2, 137±14)
6
4-2[C1A0]COMPONENT PARTS
1. Front Axle

B: AWD AT MODEL
B4M0773B
(1) O-ring
(2) Baffle plate (SFJ)
(3) Spring pin
(4) Outer race (SFJ)
(5) Snap ring
(6) Trunnion
(7) Free ring
(8) Circlip
(9) Boot band(10) Boot band
(11) Boot (BJ)
(12) BJ ASSY
(13) Baffle plate
(14) Oil seal (IN)
(15) Snap ring
(16) Bearing
(17) Housing
(18) Oil seal (OUT)(19) Tone wheel
(20) Hub bolt
(21) Hub
(22) Axle nut
Tightening torque: N´m (kg-m, ft-lb)
T1:
13±3 (1.3±0.3, 9.4±2.2)
T2:186±20 (19±2, 137±14)
7
[C1B0]4-2COMPONENT PARTS
1. Front Axle

2. Rear Axle
H4M1000B
(1) Circlip (2200 cc AT vehicles)
(2) Baffle plate (DOJ)
(3) Outer race (DOJ)
(4) Snap ring
(5) Inner race
(6) Ball
(7) Cage
(8) Circlip
(9) Boot band(10) Boot (DOJ)
(11) Boot (BJ)
(12) BJ ASSY
(13) Oil seal (IN. No. 2)
(14) Oil seal (IN. No. 3)
(15) Housing
(16) Bearing
(17) Snap ring
(18) Oil seal (OUT)(19) Tone wheel
(20) Hub bolt
(21) Hub
(22) Axle nut
Tightening torque: N´m (kg-m, ft-lb)
T1:
13±3 (1.3±0.3, 9.4±2.2)
T2:186±20 (19±2, 137±14)
8
4-2[C200]COMPONENT PARTS
2. Rear Axle

1. Front Axle
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands,
and remove front wheels.
3) Unlock axle nut.
G4M0214
4) Remove axle nut using a socket wrench.
CAUTION:
Be sure to loose and retighten axle nut after
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
5) Remove stabilizer link.
G4M0215
6) Remove DOJ/SFJ from transmission spindle.7) Remove front drive shaft assembly from hub. If
it is hard to remove, use STs.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
IBe careful not to damage oil seal lip when
removing front drive shaft.
IWhen replacing front drive shaft, also
replace inner oil seal.
G4M0216
8) Remove disc brake caliper from housing, and
suspend it from strut using a wire.
9) Remove disc rotor from hub.
If disc rotor seizes up within hub, drive disc rotor
out by installing an 8-mm bolt in screw hole on the
rotor.
G4M0217
10) Remove cotter pin and castle nut which
secure tie-rod end to housing knuckle arm.
G4M0218
9
[W1A0]4-2SERVICE PROCEDURE
1. Front Axle

11) Using a puller, remove tie-rod ball joint from
knuckle arm.
G4M0219
12) On ABS equipped models, remove ABS sen-
sor assembly and harness in advance.
H4M1138A
13) Remove transverse link ball joint from hous-
ing.
G4M0221
14) After scribing an alignment mark on camber
adjusting bolt head, remove bolts which connect
housing and strut, and disconnect housing from
strut.
G4M0222
B: DISASSEMBLY
1) Using ST1, support housing and hub securely.
2) Attach ST2 to housing and drive hub out.
ST1 927080000 HUB STAND
ST2 927060000 HUB REMOVER
G4M0223
If inner bearing race remains in the hub, remove it
with a suitable tool (commercially available).
CAUTION:
IBe careful not to scratch polished area of
hub.
IBe sure to install inner race on the side of
outer race from which it was removed.
G4M0224
10
4-2[W1B0]SERVICE PROCEDURE
1. Front Axle

3) Remove disc cover from housing.
G4M0225
4) Using a standard screwdriver, remove outer
and inner oil seals.
CAUTION:
Do not use old oil seals.
5) Using flat bladed screwdriver, remove snap
ring.
H4M1001
6) Using ST1, support housing securely.
7) Using ST2, press inner race to drive out outer
bearing.
ST1 927400000 HOUSING STAND
ST2 927100000 BEARING REMOVER
CAUTION:
IDo not remove outer race unless it is faulty.
IDiscard outer race after removal.
IDo not replace inner or outer race sepa-
rately; always replace as a unit.
G4M0227
8) Loosen bolts which secure tone wheel to hub.
Remove tone wheel (only vehicle equipped with
ABS).9) Using ST and a hydraulic press, drive hub bolts
out.
ST 927080000 HUB STAND
CAUTION:
Be careful not to hammer hub bolts. This may
deform hub.
G4M0228
C: INSPECTION
Check the removed parts for wear and damage. If
defective, replace with new ones.
CAUTION:
IIf bearing is faulty, replace it as a bearing set.
IBe sure to replace oil seal at every overhaul.
H4M1002A
D: ASSEMBLY
1) Attach hub to ST securely.
ST 927080000 HUB STAND
G4M0230
2) Using a hydraulic press, press new hub bolts
into place.
11
[W1D0]4-2SERVICE PROCEDURE
1. Front Axle

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

12) Attach hub to ST1 securely.
13) Clean dust or foreign particles from the pol-
ished surface of hub.
14) sing ST2, press bearing into hub by driving
inner race.
ST1 927080000 HUB STAND
ST2 927120000 HUB INSTALLER
G4M0235
E: INSTALLATION
1) Install transverse link ball joint to housing.
Tightening torque:
44
±6 N´m (4.5±0.6 kg-m, 32.5±4.3 ft-lb)
2) While aligning alignment mark on camber
adjusting bolt head, connect housing and strut.
CAUTION:
Use a new self-locking nut.
Tightening torque:
147
±15 N´m (15±1.5 kg-m, 108±11 ft-lb)
3) Install speed sensor and harness on housing
(only vehicle equipped with ABS).
4) Install disc rotor on hub.
5) Install disc brake caliper on housing.
Tightening torque:
59
±10 N´m (6±1 kg-m, 43±7 ft-lb)
6) Install front drive shaft.
7) Connect stabilizer link.8) Install tie-rod end ball joint on housing knuckle
arm.
Tightening torque:
27.0
±2.5 N´m (2.75±0.25 kg-m, 19.9±1.8
ft-lb)
G4M0236
9) While depressing brake pedal, tighten axle nut
and lock it securely.
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.
Tightening torque:
186
±20 N´m (19±2 kg-m, 137±14 ft-lb)
G4M0237
10) After tightening axle nut, lock it securely.
G4M0238
13
[W1E0]4-2SERVICE PROCEDURE
1. Front Axle

11) Install wheel and tighten wheel nuts to speci-
fied torque.
Tightening torque:
88
±10 N´m (9±1 kg-m, 65±7 ft-lb)
2. Rear Axle
A: REMOVAL
1. DISC BRAKE
1) Disconnect ground cable from battery.
2) Jack-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) Remove axle nut using a socket wrench.
5) Return parking brake lever and loosen adjust-
ing nut.
B4M0050A
6) Remove disc brake caliper from back plate, and
suspend it from strut using a piece of wire.
G4M0240
7) Remove disc rotor from hub.
NOTE:
If disc rotor seizes up within hub, drive it out by
installing an 8-mm bolt into bolt hole in disc rotor.
14
4-2[W2A1]SERVICE PROCEDURE
2. Rear Axle

11) Install wheel and tighten wheel nuts to speci-
fied torque.
Tightening torque:
88
±10 N´m (9±1 kg-m, 65±7 ft-lb)
2. Rear Axle
A: REMOVAL
1. DISC BRAKE
1) Disconnect ground cable from battery.
2) Jack-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) Remove axle nut using a socket wrench.
5) Return parking brake lever and loosen adjust-
ing nut.
B4M0050A
6) Remove disc brake caliper from back plate, and
suspend it from strut using a piece of wire.
G4M0240
7) Remove disc rotor from hub.
NOTE:
If disc rotor seizes up within hub, drive it out by
installing an 8-mm bolt into bolt hole in disc rotor.
14
4-2[W2A1]SERVICE PROCEDURE
2. Rear Axle