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
B
A
(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
T1
T11
T6
T8
T8
T5
T9
T10
T9
T4
T2
T7
T4
(16)
(25)
(17)
(18)
(19)
(1)
(20)
(21)
(22)
(23)
(25)
(9)
(10)
(11)
(12)
(13)
(15)
(25)
(25)
(25)
T2
T7
(25)
(14)
(25)
T7
T7
T7
(2)
(5)
(8)
(7)
T3
(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
2
ST-92768000
0
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
AA
A
(4)
(1)
(2) (3)
(1)
(5) (1)
(7)
(6)
(8)