SUBARU LEGACY 1999 Service Repair Manual

8) Disconnect parking brake cable end.
G4M0241
9) Remove bolts which secure trailing link assem-
bly to rear housing.
CAUTION:
Discard old self-locking nut. Replace with a
new one.
G4M0246
10) Remove bolts which secure lateral link assem-
bly to rear housing.
CAUTION:
Discard old self-locking nut. Replace with a
new one.
G4M0245
11) Disengage BJ from housing splines, and
remove rear drive shaft assembly. 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 rear drive shaft.
IWhen rear drive shaft is to be replaced, also
replace inner oil seal with a new one.
G4M0247
12) Remove rear ABS sensor from back plate
(only vehicle equipped with ABS).
H4M1139A
13) Remove bolts which secure rear housing to
strut, and separate the two.
G4M0249
2. DRUM BRAKE
1) Disconnect ground cable from battery.
2) Jack-up vehicle, and remove rear wheel cap
and wheels.
15
[W2A2]4-2SERVICE PROCEDURE
2. Rear 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

11) Remove bolts which secure lateral link assem-
bly to rear housing.
CAUTION:
Discard old self-locking nut. Replace with a
new one.
G4M0245
12) Disengage BJ from housing splines, and
remove rear drive shaft assembly. 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 rear drive shaft.
IWhen rear drive shaft is to be replaced, also
replace inner oil seal with a new one.
G4M0247
13) Remove bolts which secure rear housing to
strut, and separate the two.
G4M0249
B: DISASSEMBLY
1) Using ST1 and ST2, remove hub from rear
housing.
ST1 927080000 HUB STAND
ST2 927420000 HUB REMOVER
G4M0250
2) Remove back plate from rear housing.
3) Using a standard screwdriver, remove outer
and inner oil seals.
CAUTION:
Use new oil seals.
4) Using flat bladed screwdriver, remove snap
ring.
H4M1003
5) Using ST1 and ST2, remove bearing by press-
ing inner race.
ST1 927430000 HOUSING STAND
ST2 927440000 BEARING REMOVER
CAUTION:
IDo not remove bearing unless damaged.
IDo not re-use bearing after removal.
G4M0252
17
[W2B0]4-2SERVICE PROCEDURE
2. Rear Axle

6) Remove tone wheel bolts and remove tone
wheel from hub (only vehicle equipped with ABS).
7) Using ST, press hub bolts out.
ST 927080000 HUB STAND
CAUTION:
Be carful 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 a bearing is faulty, replace it as a bearing
set.
IBe sure to replace oil seal at every overhaul.
H4M1002A
D: ASSEMBLY
1) Using ST, press new hub bolt into place.
CAUTION:
IEnsure hub bolt closely contacts hub.
IUse a 12 mm (0.47 in) hole in the ST to pre-
vent hub bolt from tilting during installation.
ST 927080000 HUB STAND
G4M0230
2) 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:
IEnsure tone wheel closely contacts hub.
IBe careful not to damage tone wheel teeth.
G4M0231
18
4-2[W2C0]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

11) Using ST1 and ST2, press bearing into hub.
ST1 927080000 HUB STAND
ST2 927450000 HUB INSTALLER
G4M0262
E: INSTALLATION
1. DISC BRAKE
1) Connect rear housing assembly and strut
assembly.
CAUTION:
Use a new self-locking nut.
Tightening torque:
147
±15 N´m (15±1.5 kg-m, 108±11 ft-lb)
2) Fit BJ (bell joint) to rear housing splines.
CAUTION:
Be careful not to damage inner oil seal lip.
3) Connect rear housing assembly to lateral link
assembly.
CAUTION:
Use a new self-locking nut.
Tightening torque:
137
±20 N´m (14±2 kg-m, 101±14 ft-lb)
G4M0245
4) Connect rear housing assembly to trailing link
assembly.
CAUTION:
Use a new self-locking nut.
Tightening torque:
98 Ð 127 N´m (10 Ð 13 kg-m, 72 Ð 94
ft-lb)
G4M0246
5) Connect parking brake cable to parking brake.
6) Install disc rotor on rear housing assembly.
7) Install disc brake caliper on back plate.
Tightening torque:
52
±6 N´m (5.3±0.6 kg-m, 38.3±4.3 ft-lb)
G4M0240
8) Install rear speed sensor to back plate (only
vehicle equipped with ABS).
G4M0266
9) Bleed air from brake system. [W11B0].>
10) Adjust parking brake lever stroke by turning
adjuster.
11) Move brake lever back to apply brakes. While
depressing brake pedal, tighten axle nut using a
20
4-2[W2E1]SERVICE PROCEDURE
2. Rear Axle

socket wrench. Lock axle nut after tightening.
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.
12) 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. DRUM BRAKE
1) Connect rear housing assembly and strut
assembly.
CAUTION:
Use a new self-locking nut.
Tightening torque:
147
±15 N´m (15±1.5 kg-m, 108±11 ft-lb)
2) Fit BJ (bell joint) to rear housing splines.
CAUTION:
Be careful not to damage inner oil seal lip.
3) Connect rear housing assembly to lateral link
assembly.
CAUTION:
Use a new self-locking nut.
Tightening torque:
137
±20 N´m (14±2 kg-m, 101±14 ft-lb)
G4M0245
4) Connect rear housing assembly to trailing link
assembly.
CAUTION:
Use a new self-locking nut.
Tightening torque:
98 Ð 127 N´m (10 Ð 13 kg-m, 72 Ð 94
ft-lb)
G4M0246
5) Connect parking brake cable to parking brake.
6) Clean brake pipe connection. Using a flare-nut
wrench, connect brake pipe to wheel cylinder.
7) Connect parking brake cable to lever.
8) Install brake drum on rear housing assembly.
9) Bleed air from brake system. [W11B0].>
10) Adjust parking brake lever stroke by turning
adjuster.
11) Move brake lever back to apply brakes. While
depressing brake pedal, tighten axle nut using a
socket wrench. Lock axle nut after tightening.
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.
12) Install wheel and tighten wheel nuts to speci-
fied torque.
Tightening torque:
88
±10 N´m (9±1 kg-m, 65±7 ft-lb)
21
[W2E2]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

5) Take out DOJ outer race from shaft assembly.
6) Wipe off grease and take out balls.
CAUTION:
The grease is a special grease (grease for con-
stant velocity joint). Do not confuse with other
greases.
NOTE:
Disassemble exercising care not to lose balls (6
pcs).
B4M0227C
NOTE:
Clean all parts as necessary.
7) To remove the cage from the inner race, turn
the cage by a half pitch to the track groove of the
inner race and shift the cage.
8) Remove snap ring, which holds the inner race
to shaft, by using pliers.
9) Take out DOJ inner race.
10) Take off DOJ cage from shaft and remove
DOJ boot.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
protect the boot from scratches.
11) Place drive shaft in a vise between wooden
blocks.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden block.12) Raise boot band claws by means of screw-
driver and hammer.
B4M0689A
13) Cut and remove the boot.
CAUTION:
The boot must be replaced with a new one
whenever it is removed.
B4M0690
14) Thus, disassembly of axle is completed, but
BJ cannot be disassembled.
24
4-2[W3B1]SERVICE PROCEDURE
3. Front and Rear Drive Shafts