Subaru Legacy 2004 Service Manual
2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
WHEEL AND TIRE SYSTEM WT
DIFFERENTIALS DI
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, reassembling, inspection and ad justment of
components and diagnostics for guidance 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.
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)
All information, illustration and specifications contained in this manual are
based on the lates t product informat ion
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD. G2320GE6
BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM
(POWER STEERING)
PS
FRONT SUSPENSION
Page
1. General Description....................................................................................2
2. Wheel Alignment.........................................................................................8
3. Front Crossmember Support Plate ................ .................... .................... ...15
4. Front Stab il i z e r............... ............. .. .............. .. ............. ............. ... ............. ..16
5. Front Ball J o in t .... .. ............. ... ............. .. ............. ... ............. .. ............. .. ....... 17
6. Front Arm ... .. .............. .. ............. .. ............. ... ............. ............. .. .............. .. ..19
7. Front Stru t .... .............. ............. .. ............. .. .............. .. ............. ............. ... ....22
8. Front Cros s m e mb e r .............. .. ............. ............. ... ............. .. ............. .........26
9. General Diagnostic Table..........................................................................27
FS
FRONT SUSPENSION
1. General Description
A: SPECIFICATION
Model
Wheel arch height
−0.94 in
−0.94 in
+12
+12
−24 mm
)]
−24 mm
)]
mm (in) 376 (14.8) 381 (15.0) 376 (14.8) 429 (16.9)
Inner
wheel
Outer
wheel
mm (in) 360 (14.2) 375 (14.8) 430 (16.9)
[Tolerance:
+0.47 in
(
Camber (Tolerance: ±0°45′
Differences between RH and
LH: 45′ or less)
Caster 6°00′ 5°45′ 5°05′
Front
Steering angle (Tolerance: ±1.5°)
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)
Wheel arch height
[Tolerance:
+0.47 in
(
Camber (Tolerance: ±0°45′
Differences between RH and
Rear
LH: 45′ or less)
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)
General Description
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
−0°20′−0°15′−0°20′ 0°30′
37.3° 37.8°
33.0° 33.5°
−0°45′−0°30′ 0°00′
20
(0.78)
19.1 (0.75) 17.3 (0.68)
OUTBACK
2.5 i,
OUTBACK
3.0 R
FS-2
General Description
NOTE:
1
• Front and rear toe-ins and front camber can be
adjusted. If the toe-in or camber tol erance exceeds
specifications, adjust them.
• Other items indicated in the specification table
cannot be adjusted. If those items exceed specifications, check suspension parts and connections
for deformities; replace with new ones as required.
B
(1)
FRONT SUSPENSION
A
(1) Front
A − B = Positive: Toe-in, Negative: Toe-out
α = Each toe angle
FS-0000
FS-3
FRONT SUSPENSION
B: COMPONENT
T1
General Description
(25)
(22)
(20)
(16)
(17)
(18)
(19)
T6
(21)
(23)
(15)
T7
T7
(12)
(25)
(13)
(1)
(25)
(7)
T4
T7
T5
T8
T8
T4
(25)
T9
(8)
(6)
(3)
(4)
(24)
T3
(26)
(2)
(5)
T9
(25)
T10
(11)
(10)
T2
T7
(25)
T11
(1) Front crossmember (14) Crossmember support plate
(2) Housing T1: 20 (2.0, 14.5)
(Small type)
(9)
(14)
T7
(25)
T2
Tightening torque: N⋅m (kgf-m, ft-lb)
(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
FS-4
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 removal, installation, disass embly 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 cushioning 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.
FRONT SUSPENSION
FS-5
FRONT SUSPENSION
2
0
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
927380002 ADAPTER Used as an adapter for camber & caster gauge
(1)
(2)
ST-92738000
927680000 INSTALLER &
General Description
when measuring cambe r and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT
Used for replacing the front arm front bushing.
REMOVER SET
ST-92768000
ST20299AG000
20299AG000
(Newly adopted tool)
20299AG010
(Newly adopted tool)
REMOVER Used for replacing the front arm rear bushing.
Used with BASE (20999AG010).
BASE Used for replacing the front arm rear bushing.
Used with REMOVER (20999AG000).
ST20299AG010
FS-6
General Description
FRONT SUSPENSION
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
20299AG020
(Newly adopted tool)
ST20299AG020
20399AG000
(Newly adopted tool)
STUD BOLT
SOCKET
STRUT MOUNT
SOCKET
Used for remo ving an d instal ling t he stud bol t f or
front arm installing portion.
Used for dis assemb ling an d assem blin g the strut
mount.
ST20399AG000
2. GENERAL TOOL
TOOL NAME REMARKS
Alignment gauge Used for wheel alignment me asurement.
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.
FS-7
Wheel Alignment
FRONT SUSPENSION
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 li nk
• 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-8
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