Subaru 2004 LEGACY User manual

FUJI HEAVY INDUSTRIES LTD. G2320GE6

2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

CHASSIS SECTION

This service manual has been prepared

to provide SUBARU service personnel

with the necessary information and data

for the correct maintenance and repair

of SUBARU vehicles.

This manual includes the procedures

for maintenance, disassembling, reas-

sembling, inspection and adjustment of

components and diagnostics for guid-

ance of experienced mechanics.

Please peruse and utilize this manual

fully to ensure complete repair work for

satisfying our customers by keeping

their vehicle in optimum condition.

When replacement of parts during

repair work is needed, be sure to use

SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are

based on the latest product information

available at the time of publication

approval.

FRONT SUSPENSION FS

REAR SUSPENSION RS

WHEEL AND TIRE SYSTEM WT

DIFFERENTIALS DI

TRANSFER CASE TC

DRIVE SHAFT SYSTEM DS

ABS ABS

ABS (DIAGNOSTICS) ABS(diag)

VEHICLE DYNAMICS CONTROL (VDC) VDC

VEHICLE DYNAMICS CONTROL (VDC)

(DIAGNOSTICS) VDC(diag)

BRAKE BR

PARKING BRAKE PB

POWER ASSISTED SYSTEM

(POWER STEERING) PS

FRONT SUSPENSION FS

Page

1. General Description ....................................................................................2

2. Wheel Alignment.........................................................................................8

3. Front Crossmember Support Plate ...........................................................15

4. Front Stabilizer..........................................................................................16

5. Front Ball Joint..........................................................................................17

6. Front Arm ..................................................................................................19

7. Front Strut.................................................................................................22

8. Front Crossmember ..................................................................................26

9. General Diagnostic Table..........................................................................27

FS-2

FRONT SUSPENSION General Description

1. General Description

A: SPECIFICATION

Model

Sedan Wagon

2.0 i 2.5 i 2.0 GT 3.0 R 2.0 i 2.5 i 2.0 GT 3.0 R

OUTBACK

2.5 i,

OUTBACK

3.0 R

Front

Wheel arch height

mm (in) 376 (14.8) 381 (15.0) 376 (14.8) 429 (16.9)

[Tolerance: +12 −24 mm

(+0.47 in −0.94 in)]

Camber (Tolerance: ±0°45′

Differences between RH and

LH: 45′or less) −0°20′−0°15′−0°20′0°30′

Caster 6°00′5°45′5°05′

Steering angle (Toler-

ance: ±1.5°)

Inner

wheel 37.3°37.8°

Outer

wheel 33.0°33.5°

Toe-in mm (in) 0±3 (0±0.12) Toe angle (sum of both wheels): 0°±0°15′

Kingpin angle 13°50′13°45′13°50′12°25′

Diameter of stabilizer mm (in) 20 (0.79) 21 (0.83) 20 (0.79) 21 (0.83)

Rear

Wheel arch height

mm (in) 360 (14.2) 375 (14.8) 430 (16.9)

[Tolerance: +12 −24 mm

(+0.47 in −0.94 in)]

Camber (Tolerance: ±0°45′

Differences between RH and

LH: 45′or less) −0°45′−0°30′0°00′

Toe-in mm (in) 0±3 (0±0.12) Toe angle (sum of both wheels): 0°±0°15′

Thrust angle (Tolerance: ±0°30′)0°

Diameter of stabilizer mm (in) 17.3 (0.68) 19.1 (0.75) 20

(0.78) 19.1 (0.75) 17.3 (0.68)

FS-3

FRONT SUSPENSION

General Description

NOTE:

• Front and rear toe-ins and front camber can be

adjusted. If the toe-in or camber tolerance exceeds

specifications, adjust them.

• Other items indicated in the specification table

cannot be adjusted. If those items exceed specifi-

cations, check suspension parts and connections

for deformities; replace with new ones as required.

(1) Front

A −B = Positive: Toe-in, Negative: Toe-out

α= Each toe angle

FS-0000

(1)

FS-4

FRONT SUSPENSION General Description

B: COMPONENT

(1) Front crossmember (14) Crossmember support plate

(Small type) Tightening torque: N

⋅

m (kgf-m, ft-lb)

(2) Housing T1: 20 (2.0, 14.5)

(3) Ball joint (15) Jack-up plate T2: 25 (2.5, 18.1)

(4) Front arm (16) Dust seal T3: 39 (4.0, 28.8)

(5) Support plate (17) Strut mount T4: 45 (4.6, 33.2)

(6) Rear bushing (18) Upper spring seat T5: 50 (5.1, 36.9)

(7) Front bushing (19) Dust cover T6: 55 (5.6, 41)

(8) Stud bolt (20) Helper T7: 60 (6.1, 44.3)

(9) Stabilizer link (21) Coil spring T8: 95 (9.7, 70.1)

(10) Bracket (22) Damper strut T9: 110 (11.2, 81.1)

(11) Bushing (23) Adjusting bolt T10: 150 (15.3, 110.6)

(12) Stabilizer (24) Castle nut T11: 175 (17.8, 129)

(13) Crossmember support plate

(Large type) (25) Self-locking nut

(26) Cotter pin

FS-00131

T11

T10

(16)

(25)

(17)

(18)

(19)

(1)

(20)

(21)

(22)

(23)

(25)

(9)

(10)

(11)

(12)

(13)

(15)

(25)

(14)

(25)

(2)

(5)

(8)

(7)

(3)

(4)

(24)

(26)

(6)

FS-5

FRONT SUSPENSION

General Description

C: CAUTION

• Wear work clothing, including a cap, protective

goggles, and protective shoes during operation.

• Before removal, installation or disassembly, be

sure to clarify the failure. Avoid unnecessary re-

moval, installation, disassembly and replacement.

• Use SUBARU genuine grease or the equivalent.

Do not mix grease, etc. with that of another grade

or from other manufacturers.

• Before securing a part on a vice, place cushion-

ing material such as wood blocks, aluminum plate,

or cloth between the part and the vice.

• Be sure to tighten fasteners including bolts and

nuts to the specified torque.

• Place shop jacks or rigid racks at the specified

points.

FS-6

FRONT SUSPENSION General Description

D: PREPARATION TOOL

1. SPECIAL TOOL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

927380002 ADAPTER Used as an adapter for camber & caster gauge

when measuring camber and caster.

(1) 28199AC000 PLATE

(2) 28199AC010 BOLT

927680000 INSTALLER &

REMOVER SET Used for replacing the front arm front bushing.

20299AG000

(Newly adopted tool) REMOVER Used for replacing the front arm rear bushing.

Used with BASE (20999AG010).

20299AG010

(Newly adopted tool) BASE Used for replacing the front arm rear bushing.

Used with REMOVER (20999AG000).

(1)

(2)

ST-92738000

ST-92768000

ST20299AG000

ST20299AG010

FS-7

FRONT SUSPENSION

General Description

2. GENERAL TOOL

20299AG020

(Newly adopted tool) STUD BOLT

SOCKET Used for removing and installing the stud bolt for

front arm installing portion.

20399AG000

(Newly adopted tool) STRUT MOUNT

SOCKET Usedfor disassembling and assembling the strut

mount.

TOOL NAME REMARKS

Alignment gauge Used for wheel alignment measurement.

Turning radius gauge Used for wheel alignment measurement.

Toe-in gauge Used for toe-in measurement.

Dial gauge Used for damper strut measurement.

Coil spring compressor Used for strut assembly/disassembly.

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

ST20299AG020

ST20399AG000

FS-8

FRONT SUSPENSION Wheel Alignment

2. Wheel Alignment

A: INSPECTION

Check the following items before taking wheel alignment measurement.

Check items before taking wheel alignment measurement:

• Tire inflation pressure

• Unbalanced right and left tire wear, size difference

• Tire runout

• Excessive play and wear in ball joint

• Excessive play and wear in tie rod end

• Excessive play in wheel bearing

• Right and left wheel base imbalance

• Deformation and excessive play in steering link

• Deformation and excessive play in suspension parts

Check, adjust and measure the wheel alignment in accordance with the procedures indicated in the figure.

Wheel arch height (front and rear wheels)

<Ref. to FS-9, WHEEL ARCH HEIGHT, INSPECTION, Wheel Alignment.>

↓

Camber (front and rear wheels)

<Ref. to FS-10, CAMBER, INSPECTION, Wheel Alignment.>

↓

Caster (front wheel)

<Ref. to FS-11, CASTER, INSPECTION, Wheel Alignment.>

↓

Steering angle

<Ref. to FS-11, STEERING ANGLE, INSPECTION, Wheel Alignment.>

↓

Front wheel toe-in

<Ref. to FS-12, FRONT WHEEL TOE-IN, INSPECTION, Wheel Alignment.>

↓

Rear wheel toe-in

<Ref. to FS-12, REAR WHEEL TOE-IN, INSPECTION, Wheel Alignment.>

↓

Thrust angle

<Ref. to FS-14, THRUST ANGLE, INSPECTION, Wheel Alignment.>

FS-9

FRONT SUSPENSION

Wheel Alignment

1. WHEEL ARCH HEIGHT

1) Park the vehicle on a level surface.

2) Set the vehicle under “curb weight” condition.

(Make the luggage compartment empty, install the

spare tire, jack and service tools, and top up the

fuel tank.)

3) Set the steering wheel in a straight-ahead posi-

tion, and stabilize the suspensions by moving the

vehicle straight more than 5 m (16 ft).

4) Suspend a thread from wheel arch (point “A” in

the figure below) to determine the point directly

above the center of wheel.

5) Measure the distance between the point “A” and

the center of wheel.

(1) Wheel arch height (4) Front wheel arch height (7) Point of measurement

(2) Front fender (5) Rear wheel arch height (8) Tip end of spindle

(3) Rear quarter (6) Flange bend line

Wheel arch height standard value mm (in) (Tolerance ±12 mm)

Model

Sedan Wagon

2.0 i 2.5 i 2.0 GT 3.0 R 2.0 i, 2.5 i 2.0 GT, 3.0 R

OUTBACK

2.5 i,

OUTBACK

3.0 R

Front 376 (14.8) 381 (15.0) 376 (14.8) 429 (16.9)

Rear 360 (14.2) 375 (14.8) 430 (16.9)

FS-00125

(4)

(1)

(2) (3)

(1)

(5) (1)

(7)

(6)

(8)

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