Subaru IMPREZA 2004 Service Manual
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Subaru IMPREZA 2004 Service Manual

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Table of Contents

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See also: Service Manual , Owner's Manual
2004 IMPREZA SERVICE MANUAL
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.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FRONT SUSPENSION
REAR SUSPENSION
WHEEL AND TIRE SYSTEM
DIFFERENTIALS
TRANSFER CASE
DRIVE SHAFT SYSTEM
ABS
ABS (DIAGNOSTICS)
BRAKE
PARKING BRAKE
POWER ASSISTED SYSTEM
(POWER STEERING)
FS
RS
WT
DI
TC
DS
ABS
ABS(diag)
BR
PB
PS
G1870GE5

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Summary of Contents for Subaru IMPREZA 2004

  • Page 1 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 2 FRONT SUSPENSION Page General Description ..................2 Wheel Alignment ..................6 Front Transverse Link ................15 Front Ball Joint ..................18 Front Strut ....................19 Front Stabilizer ..................23 Front Crossmember ..................24 Sub Frame ....................25 Front Support Arm..................27 General Diagnostic Table................28...

  • Page 3: General Description

    General Description FRONT SUSPENSION 1. General Description A: SPECIFICATIONS Sedan Wagon Model OUTBACK Non-turbo Turbo Non-turbo Turbo Camber (tolerance: ±0°45′) −0°15′ −0°25′ −0°10′ −0°20′ −0°05′ Caster 3°25′ 3°30′ 3°25′ 3°30′ 3°25′ 0±3 (0±0.12) Each toe angle: ±0°07′30″ Toe-in mm (in) Kingpin angle 14°20′...
  • Page 4 General Description FRONT SUSPENSION B: COMPONENT (17) (28) (28) (18) (19) (28) (20) (33) (16) (21) (22) (11) (34) (27) (28) (23) (10) (11) (28) (28) (24) (31) (14) (15) (28) (12) (13) (15) (27) (28) (25) (12) (28) (10) (29) (26) (28)
  • Page 5 • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary re- moval, installation, disassembly, and replacement. • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease etc. with that of another grade or from other manufacturers.

  • Page 6: Wheel Alignment

    General Description FRONT SUSPENSION D: PREPARATION TOOL 1. SPECIAL TOOLS 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 ST-927380002 927680000 INSTALLER & Used for replacing transverse link bushing.
  • Page 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 air pressure • unbalanced right and left tire wear, size difference • tire run-out •...
  • Page 8 Wheel Alignment FRONT SUSPENSION 1. WHEEL ARCH HEIGHT 1) Set the vehicle on a level surface. 2) Set the vehicle to “curb weight” conditions. (Empty luggage compartment, install spare tire, jack, service tools, and top up fuel tank.) 3) Set the steering wheel in a straight line, then remove the vehicle straight ahead more than 5 m (16 ft) to settle the suspension.
  • Page 9 Wheel Alignment FRONT SUSPENSION 2. CAMBER NOTE: Moving the adjusting bolt by one scale graduation • Inspection changes camber by approx. 0°15′. 1) Place the front wheel on turning radius gauge. Make sure ground contacting surfaces of front and rear wheels are set at the same height. 2) Set the ST into the center of wheel, and then in- stall the wheel alignment gauge.
  • Page 10 Wheel Alignment FRONT SUSPENSION Camber is increased. Rotate camber adjusting bolt LH counterclockwise. Rotate camber adjusting bolt RH clockwise. FS-00009 FS-00010 Camber is decreased. Rotate camber adjusting bolt LH clockwise. Rotate camber adjusting bolt RH counterclockwise. FS-00009 FS-00010 4) Tighten the new two self-locking nuts. ST 927380002 ADAPTER Tightening torque:...
  • Page 11 Wheel Alignment FRONT SUSPENSION 4. STEERING ANGLE 4) Measure the distance “B” between right and left marks. Toe-in can then be obtained by the follow- • Inspection ing equation: 1) Place the vehicle on a turning radius gauge. A − − − − B = Toe-in 2) While depressing the brake pedal, turn the steer- ing wheel fully to the right and left.
  • Page 12 Wheel Alignment FRONT SUSPENSION 6. REAR WHEEL TOE-IN • Inspection Toe-in: 0 ± ± ± ± 3 mm (0 ± ± ± ± 0.12 in) For rear toe-in inspection procedure, refer to FRONT WHEEL TOE-IN procedure. <Ref. to FS-10, FRONT WHEEL TOE-IN, INSPEC- TION, Wheel Alignment.>...
  • Page 13 Wheel Alignment FRONT SUSPENSION Toe-in is increased. Rotate camber adjusting bolt LH clockwise. Rotate camber adjusting bolt RH counterclockwise. FS-00018 FS-00019 Toe-in is decreased. Rotate camber adjusting bolt LH counterclockwise. Rotate camber adjusting bolt RH clockwise. FS-00018 FS-00019 3) Tighten a new self-locking nut. Tightening torque: 100 N·m (10.2 kgf-m, 74 ft-lb) FS-12...
  • Page 14 Wheel Alignment FRONT SUSPENSION 7. THRUST ANGLE Thrust angle: 0 °± °± °± °± 20 ′ ′ ′ ′ • Inspection Less than 20 ′ ′ ′ ′ when “L” is less than 15 mm 1) Position the vehicle on a level surface. (0.6 in).
  • Page 15 Wheel Alignment FRONT SUSPENSION Here, use only positive toe-in values from each wheel to substitute for α and β in the equation. FS-00976 (1) Front (2) Body center line FS-14...

  • Page 16: Front Transverse Link

    Front Transverse Link FRONT SUSPENSION 3. Front Transverse Link 9) Remove the bolt securing transverse link to crossmember, and then extract the transverse link A: REMOVAL from crossmember. 1) Set the vehicle on a lift. 2) Lift-up the vehicle and remove the wheel. 3) Remove the sub frame.
  • Page 17 Front Transverse Link FRONT SUSPENSION 5) Tighten the following points in the order shown 2. REAR BUSHING below when tires are in full contact with the ground 1) Scribe an aligning mark on the transverse link and vehicle is curb weight. and rear bushing.
  • Page 18 Front Transverse Link FRONT SUSPENSION E: INSPECTION 1) Check the transverse link for wear, damage and cracks, and correct or replace if defective. 2) Check the bushings for cracks, fatigue or dam- age. 3) Check the rear bushing for oil leaks. FS-17...

  • Page 19: Front Ball Joint

    Front Ball Joint FRONT SUSPENSION 4. Front Ball Joint C: INSPECTION 1) Measure the play of ball joint by the following A: REMOVAL procedures. Replace with a new one when the play 1) Remove the wheel. exceeds specified value. 2) Pull out the cotter pin from ball stud, remove the (1) With 686 N (70 kgf, 154 lb) loaded in direc- castle nut, and extract the ball stud from transverse tion shown in the figure, measure the dimension...

  • Page 20: Front Strut

    Front Strut FRONT SUSPENSION 5. Front Strut 6) Remove the three nuts securing the strut mount to body. A: REMOVAL 1) Remove the wheel. 2) Remove the bolt securing the brake hose from strut. FS-00037 3) Scribe an alignment mark on the camber adjust- ing bolt which secures the strut to housing.
  • Page 21 Front Strut FRONT SUSPENSION C: DISASSEMBLY (4) Fully contract the piston rod. (5) Repeat three or four times from first step. 1) Using a coil spring compressor, compress the coil spring. NOTE: After completely purging air from strut, be sure to place the strut with piston rod facing up.
  • Page 22 Front Strut FRONT SUSPENSION (2 kgf, 4 lb) in the opposite direction of “W”, then NOTE: read dial gauge indication: P Ensure that the upper spring seat is positioned as shown in the figure. FS-00046 FS-00044 Limit of play (P 0.8 mm (0.031 in) (1) Outside of body If the play is greater than limit, replace the strut.
  • Page 23 Front Strut FRONT SUSPENSION 2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill, make holes in areas shown in the figure. FS-00047 (1) 40 mm (1.57 in) 2. STi MODEL CAUTION: • Before handling gas filled struts, be sure to wear goggles to protect eyes from gas, oil and filings.

  • Page 24: Front Stabilizer

    Front Stabilizer FRONT SUSPENSION 6. Front Stabilizer B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL NOTE: 1) Jack-up the front part of the vehicle and support • Install the bushing (on front crossmember side) it with rigid racks. while aligning it with paint mark on stabilizer.

  • Page 25: Front Crossmember

    Front Crossmember FRONT SUSPENSION 7. Front Crossmember B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. Always tighten the bushing when tires are in full 2) Lift-up the vehicle, and then remove the front contact with the ground and vehicle is curb weight.

  • Page 26: Sub Frame

    Sub Frame FRONT SUSPENSION 8. Sub Frame B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Lift-up the vehicle. Replace the M12 bolt with a new one. 2) Remove the under cover. 3) Remove the bolt cover. Tightening torque: T1: 34 N·m (3.5 kgf-m, 25 ft-lb) T2: 55 N·m (5.6 kgf-m, 41 ft-lb)
  • Page 27 Sub Frame FRONT SUSPENSION C: INSPECTION 1) Check that there is no damage and distortion at the sub frame. 2) Check that the bolts are tightened with the spec- ified torque. If there is looseness, tighten to the specified torque. Tightening torque: T1: 34 N·m (3.5 kgf-m, 25 ft-lb) T2: 55 N·m (5.6 kgf-m, 41 ft-lb)

  • Page 28: Front Support Arm

    Front Support Arm FRONT SUSPENSION 9. Front Support Arm A: REMOVAL 1) Set the vehicle on a lift. 2) Lift-up the vehicle. 3) Remove the under cover. 4) Remove the four bolts and jack-up plate. FS-00075 5) Remove the two nuts at both ends of arm re- spectively.

  • Page 29: General Diagnostic Table

    General Diagnostic Table FRONT SUSPENSION 10.General Diagnostic Table A: INSPECTION 1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT Possible causes Countermeasures (1) Permanent distortion or breakage of coil spring Replace. (2) Unsmooth operation of damper strut and/or shock absorber Replace.
  • Page 30 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 31 REAR SUSPENSION Page General Description ..................2 Wheel Alignment ..................10 Rear Stabilizer...................11 Rear Trailing Link ..................12 Rear Strut....................16 Lateral link....................17 Rear Crossmember...................21 General Diagnostic Table................22...

  • Page 32: General Description

    General Description REAR SUSPENSION 1. General Description A: SPECIFICATIONS Sedan Wagon Model OUTBACK Non-turbo Turbo Non-turbo Turbo Camber (tolerance: ±0°45′) −1°25′ −1°30′ −1°15′ −1°20′ −1°10′ 0±3 (0±0.12) Each toe angle: ±0°09′ Toe-in mm (in) Thrust angle (tolerance: ±0°30′) 0° Wheel arch height [tolerance: −24 mm (in)

  • Page 33: Rear Suspension

    General Description REAR SUSPENSION B: COMPONENT 1. REAR SUSPENSION • AWD MODEL (20) (22) (19) (21) (22) (23) (18) (24) (22) (17) (28) (25) (22) (22) (26) (11) (12) (29) (10) (13) (27) (22) (16) (22) (14) (10) (30) (22) (15) (22) (22)
  • Page 34 General Description REAR SUSPENSION Stabilizer (15) Trailing link front bushing (30) Stabilizer link (STi model) Stabilizer bracket (16) Trailing link bracket (31) Rear lateral link (STi model) Stabilizer bushing (17) Cap (Protection) Clamp (18) Washer Tightening torque: N·m (kgf-m, ft-lb) Floating bushing (19) Rear crossmember...
  • Page 35 General Description REAR SUSPENSION • FWD model (15) (16) (17) (14) (18) (19) (20) (10) (13) (21) (11) (12) RS-00099 Adjusting bolt (12) Trailing link front bushing Tightening torque: N·m (kgf-m, ft-lb) Adjusting wheel (13) Trailing link bracket T1: 20 (2.0, 14.5) Rear lateral link (14) Rear crossmember...
  • Page 36 • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary re- moval, installation, disassembly, and replacement. • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease etc. with that of another grade or from other manufacturers.
  • Page 37 General Description REAR SUSPENSION D: PREPARATION TOOL 1. SPECIAL TOOLS 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 ST-927380002 927720000 INSTALLER & Used for replacing front bushing.
  • Page 38 General Description REAR SUSPENSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 28099PA100 REMOVER Used for removing DOJ. ST28099PA100 927710000 INSTALLER & Used for replacing lateral link bushing. REMOVER ST-927710000 927700000 INSTALLER & Used for replacing lateral link bushing. REMOVER ST-927700000 927690000 INSTALLER & Used for replacing lateral link bushing.

  • Page 39: Wheel Alignment

    General Description REAR SUSPENSION 2. GENERAL PURPOSE TOOLS 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. Transmission jack Used for suspension assembly/disassembly. Bearing puller Used for removing bushings.
  • Page 40 Wheel Alignment REAR SUSPENSION 2. Wheel Alignment A: INSPECTION NOTE: Front and rear wheel alignment must be simulta- neously measured and/or adjusted. Follow the pro- cedure in “FS” section “Wheel Alignment” for measurement and/or adjustment of wheel align- ment. <Ref. to FS-6, INSPECTION, Wheel Align- ment.>...

  • Page 41: Rear Stabilizer

    Rear Stabilizer REAR SUSPENSION 3. Rear Stabilizer B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL NOTE: 1) Lift-up the vehicle. • Install the stabilizer bushing while aligning it with 2) Remove the stabilizer link. paint mark on stabilizer. •...

  • Page 42: Rear Trailing Link

    Rear Trailing Link REAR SUSPENSION 4. Rear Trailing Link C: DISASSEMBLY A: REMOVAL 1. FRONT BUSHING 1) Loosen the rear wheel nuts. Using the ST, press the front bushing out of place. 2) Lift-up the vehicle, and then remove the rear ST 927720000 INSTALLER &...
  • Page 43 Rear Trailing Link REAR SUSPENSION 2. REAR BUSHING D: ASSEMBLY Using the ST, press the rear bushing out of place. 1. FRONT BUSHING ST 927730000 INSTALLER & REMOVER Using the ST, press the bushing into trailing link. ST 927720000 INSTALLER & REMOVER CAUTION: Turn the ST plunger upside down and press it until the plunger end surface contacts the trail-...
  • Page 44 Rear Trailing Link REAR SUSPENSION 2. REAR BUSHING 2) Press the ST plunger until the bushing flange protrudes beyond trailing link. 1) Using the ST, press the bushing into trailing link. ST 927730000 INSTALLER & REMOVER ST 927730000 INSTALLER & REMOVER NOTE: If it is difficult to press the bushing into trailing link, apply water-diluted TIRE LUBE to the inner surface...
  • Page 45 Rear Trailing Link REAR SUSPENSION 3) Turn the trailing link upside down. Press the ST plunger in the opposite direction that outlines in the former procedure until bushing is correctly posi- tioned in trailing link. ST 927730000 INSTALLER & REMOVER RS-00020 (1) Press (2) Plunger...

  • Page 46: Rear Strut

    Rear Strut REAR SUSPENSION 5. Rear Strut B: INSTALLATION 1) Secure the strut mount to vehicle body using a A: REMOVAL new self-locking nut. 1) Remove the rear seat cushion and backrest. Tightening torque: (Sedan model) 20 N·m (2.0 kgf-m, 14.5 ft-lb) 2) Remove the strut cap of quarter trim.

  • Page 47: Lateral Link

    Lateral link REAR SUSPENSION 6. Lateral link 7) Remove the DOJ from rear differential using tire lever. (VA-type) A: REMOVAL NOTE: 1) Loosen the wheel nuts. Lift-up the vehicle and The side spline shaft circlip comes out together remove wheel. with the shaft.
  • Page 48 Lateral link REAR SUSPENSION B: INSTALLATION 3) Using the ST, press the bushing out of place. Install in the reverse order of removal. Observe the following instructions. • Installation of DOJ to differential: <Ref. to DS-45, INSTALLATION, Rear Drive Shaft.> CAUTION: •...
  • Page 49 Lateral link REAR SUSPENSION 3) Using the ST, press the bushing into place. 4) Press the ST plunger until bushing flange pro- trudes beyond lateral link. RS-00030 RS-00031 (1) Press (1) Press (2) Bushing (2) Plunger (3) Lateral link (3) Lateral link (4) Flange RS-19...
  • Page 50 Lateral link REAR SUSPENSION 5) Turn the lateral link upside down. Press the ST plunger in opposite direction that outlined in the former procedure until bushing is correctly posi- tioned in trailing link. RS-00032 (1) Press (2) Plunger (3) Lateral link E: INSPECTION Visually check the lateral links for damage or bends.

  • Page 51: Rear Crossmember

    Rear Crossmember REAR SUSPENSION 7. Rear Crossmember 4) Remove the bolt securing crossmember to body, and then remove the crossmember. A: REMOVAL 1. AWD MODEL CAUTION: Do not subject the ABS wheel speed sensor harness to excessive tension. 1) Separate the front exhaust pipe and rear ex- haust pipe.

  • Page 52: General Diagnostic Table

    General Diagnostic Table REAR SUSPENSION 8. General Diagnostic Table A: INSPECTION 1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT Possible causes Countermeasures (1) Permanent distortion or breakage of coil spring Replace. (2) Unsmooth operation of damper strut or shock absorber Replace.
  • Page 53 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 54 WHEEL AND TIRE SYSTEM Page General Description ..................2 Tire ......................4 Steel Wheel....................5 Aluminum Wheel ..................6 Wheel Balancing ..................7 “T-type” Tire ....................8 Full Wheel Cap....................9 General Diagnostics Table................10...

  • Page 55: General Description

    General Description WHEEL AND TIRE SYSTEM 1. General Description A: SPECIFICATIONS WT-00001 (1) Offset (2) P.C.D. Rim offset P.C.D. Specifications Tire size Rim size mm (in) mm (in) 14 × 5 1/2JJ BASE, TS 185/70R14 88H 15 × 6JJ 195/60R15 88H 55 (2.17) 16 ×...

  • Page 56: Tire

    General Description WHEEL AND TIRE SYSTEM 1. SERVICE DATA Item Axial runout Radial runout Steel wheel 1.5 mm (0.059 in) Aluminum wheel 1.0 mm (0.039 in) 2. ADJUSTING PARTS Wheel balance Standard Service limit Dynamic unbalance Less than 5 g (0.18 oz) Balance weight part number Weight (For steel wheel)
  • Page 57 Tire WHEEL AND TIRE SYSTEM 2. Tire A: INSPECTION 1) Take stone, glass, nail etc. off from tread groove. 2) Replace the tire if as follows. CAUTION: When replacing a tire, make sure to use only the same size, construction and load range tire as originally installed.

  • Page 58: Steel Wheel

    1.5 mm (0.059 in) bolt hole with hub bolt. 3) Temporarily attach the wheel nuts to hub bolts. (In the case of aluminum wheel, use SUBARU gen- uine wheel nut for aluminum wheel.) 4) Manually tighten the nuts making sure the wheel hub hole is aligned correctly to guide portion of hub.

  • Page 59: Aluminum Wheel

    Aluminum Wheel WHEEL AND TIRE SYSTEM 4. Aluminum Wheel A: REMOVAL Refer to Steel Wheel for removal procedure of alu- minum wheels. <Ref. to WT-5, REMOVAL, Steel Wheel.> B: INSTALLATION Refer to Steel Wheel for installation procedure of aluminum wheels. <Ref. to WT-5, INSTALLATION, Steel Wheel.>...

  • Page 60: Wheel Balancing

    Wheel Balancing WHEEL AND TIRE SYSTEM 5. Wheel Balancing B: INSPECTION 1) Proper wheel balance may be lost if the tire is re- A: REPLACEMENT paired or if it wears. Check the tire for dynamic bal- 1) Remove the balance weights. ance, and repair as necessary.

  • Page 61: T-Type" Tire

    “T-type” Tire WHEEL AND TIRE SYSTEM 6. “T-type” Tire A: NOTE “T-type” tire for temporary use is prepared as a spare tire. CAUTION: • Do not use a tire chain with the “T-type” tire. Because of the smaller tire size, a tire chain will not fit properly and will result in damage to the vehicle and the tire.

  • Page 62: Full Wheel Cap

    Full Wheel Cap WHEEL AND TIRE SYSTEM 7. Full Wheel Cap A: REMOVAL Pry off the full wheel cap with a wheel cap remover inserted between openings on cap. WT-00028 B: INSTALLATION Align the valve hole in wheel cap with the valve on wheel and secure the wheel cap by tapping four points by hand.

  • Page 63: General Diagnostics Table

    General Diagnostics Table WHEEL AND TIRE SYSTEM 8. General Diagnostics Table A: INSPECTION Symptom Possible cause Corrective action Wheel wobble. Improperly inflated tire Adjust the tire pressure. Uneven wear Check the tire referring to Abnormal tire wear in this table, carry out the procedure and replace the tire.
  • Page 64 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 65 DIFFERENTIALS Page General Description ..................2 Differential Gear Oil...................25 Front Differential..................27 Rear Differential for T-type................28 Rear Differential for VA-type ..............54 Rear Differential Front Oil Seal ..............69 Rear Differential Side Oil Seal ..............71 Rear Differential Member ................76 General Diagnostic Table................77...
  • Page 66 General Description DIFFERENTIALS 1. General Description A: SPECIFICATIONS When replacing a rear differential assembly, select the correct one according to the following table. NOTE: Using the different rear differential assembly causes the drive line and tires to “drag” or emit abnormal noise. 1.6 L 2.0 L MODEL...
  • Page 67 General Description DIFFERENTIALS • Identification CAUTION: Each oil manufacturer has its base oil and addi- tives. Thus, do not mix two or more brands. GL-5 ( C) -30 -26 -15 -5 0 25 30 ( F) -22 -15 23 32 DI-00001 75W -90 •...
  • Page 68 General Description DIFFERENTIALS 2. ADJUSTING PARTS • VA-type Front and rear bearing preload at com- 12.7 — 32.4 New bearing panion flange bolt hole N (kgf, lb) (1.3 — 3.3, 2.9 — 7.3) Part No. Length mm (in) 32288AA040 52.3 (2.059) 32288AA050 52.5 (2.067) 31454AA100...
  • Page 69 General Description DIFFERENTIALS Part No. Thickness mm (in) 0.925 — 0.950 803135011 (0.0364 — 0.0374) 0.950 — 0.975 803135012 (0.0374 — 0.0384) Side gear thrust washer 0.975 — 1.000 803135013 (0.0384 — 0.0394) 1.000 — 1.025 803135014 (0.0394 — 0.0404) 1.025 —...
  • Page 70 General Description DIFFERENTIALS Part No. Thickness mm (in) 383495200 3.09 (0.1217) 383505200 3.12 (0.1228) 383515200 3.15 (0.1240) 383525200 3.18 (0.1252) 383535200 3.21 (0.1264) 383545200 3.24 (0.1276) 383555200 3.27 (0.1287) 383565200 3.30 (0.1299) 383575200 3.33 (0.1311) Pinion height adjusting shim 383585200 3.36 (0.1323) 383595200 3.39 (0.1335)
  • Page 71 General Description DIFFERENTIALS Part No. Length mm (in) 383705200 2.59 (0.1020) 383715200 2.57 (0.1012) 383725200 2.55 (0.1004) 383735200 2.53 (0.0996) 383745200 2.51 (0.0988) 383755200 2.49 (0.0980) 383765200 2.47 (0.0972) Preload adjusting washer 383775200 2.45 (0.0965) 383785200 2.43 (0.0957) 383795200 2.41 (0.0949) 383805200 2.39 (0.0941) 383815200...
  • Page 72 General Description DIFFERENTIALS B: COMPONENT 1. REAR DIFFERENTIAL FOR T-TYPE WITHOUT LSD ( 1 ) (18) (19) (21) ( 2 ) (20) ( 3 ) ( 4 ) (19) ( 5 ) (20) (18) (21) ( 1 ) (23) (22) (25) (26) (27)
  • Page 73 General Description DIFFERENTIALS 2. REAR DIFFERENTIAL FOR T-TYPE WITH LSD (27) (25) (21) (26) (22) (20) (23) (15) (19) (24) (13) (17) (18) (16) (14) (14) (15) (13) (16) (17) (10) (11) (12) DI-00402 Pinion crown gear and drive pin- (14) O-ring (26)
  • Page 74 General Description DIFFERENTIALS 3. REAR DIFFERENTIAL FOR VA-TYPE (18) (19) (20) (19) (17) (16) (15) (14) (30) (13) (10) (11) (12) DI-00403 Pinion crown gear and drive pinion (13) Lock plate (26) Gasket (14) Side bearing (27) Oil filler plug Pinion height adjusting shim (15) O-ring...
  • Page 75 General Description DIFFERENTIALS 4. REAR DIFFERENTIAL MOUNTING SYSTEM DI-00312 Differential front member Differential mount bracket Tightening torque: N·m (kgf-m, ft-lb) Plate Differential mount front cover T1: 20 (2.0, 14.5) Crossmember T2: 33 (3.4, 24.3) Differential rear member T3: 65 (6.6, 47.9) Differential mount lower bracket T4: 70 (7.1, 51.6) Stopper...
  • Page 76 • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Use SUBARU genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with that of another grade or from other manufacturers.
  • Page 77 General Description DIFFERENTIALS D: PREPARATION TOOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398477701 HANDLE Used for installing front and rear bearing cone. ST-398477701 398477702 DRIFT Used press-fitting the bearing cone of differential carrier (rear). ST-398477702 398217700 ATTACHMENT SET Stand for rear differential carrier disassembly and assembly.
  • Page 78 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498427200 FLANGE WRENCH • Used for stopping rotation of companion flange when loosening and tightening self-lock nut. • For T-type. (Except for STi model with mechanical LSD) ST-498427200 398467700 DRIFT Used for removing pinion, pilot bearing and front bearing cone.
  • Page 79 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock REMOVER pin. ST-899904100 498247001 MAGNET BASE • Used for measuring backlash between side gear and pinion, and hypoid gear. • Used with DIAL GAUGE (498247100). ST-498247001 498247100 DIAL GAUGE...
  • Page 80 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398177700 INSTALLER • Used for installing rear bearing cone. • For T-type. ST-398177700 398457700 ATTACHMENT • Used for removing side bearing retainer. • For T-type. ST-398457700 398477703 DRIFT2 • Used for press-fitting the bearing race (rear) of differential carrier.
  • Page 81 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507702 DUMMY SHAFT • Used for adjusting pinion height and preload. • For T-type. ST-398507702 398507703 DUMMY COLLAR • Used for adjusting pinion height and preload. • For T-type. ST-398507703 398517700 REPLACER •...
  • Page 82 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398507701 DIFFERENTIAL • Used for adjusting pinion height. CARRIER GAUGE • For T-type. ST-398507701 398527700 PULLER ASSY • Used for removing front oil seal. • Used for removing side bearing cup. • For T-type. ST-398527700 398227700 WEIGHT...
  • Page 83 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398237700 GAUGE • Used for installing side bearing. • For T-type. ST-398237700 28099PA100 DRIVE SHAFT • Used for removing rear drive shaft from rear REMOVER differential. • For T-type. ST28099PA100 498175500 INSTALLER •...
  • Page 84 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498447100 INSTALLER • Used for installing oil seal. • For VA-type. ST-498447100 399520105 SEAT • Used for removing side bearing cone. • Used with PULLER SET (899524100). • For VA-type. ST-399520105 399703600 PULLER ASSY Used for removing companion flange.
  • Page 85 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498505501 DIFFERENTIAL • Used for adjusting pinion height. CARRIER GAUGE • For VA-type. ST-498505501 498447110 DRIFT • Used for press-fitting the bearing race (front) of differential carrier. • For VA-type. ST-498447110 498447150 DUMMY SHAFT •...
  • Page 86 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 32285AA000 DUMMY COLLAR • Used for adjusting pinion height and pre-load. • For VA-type. ST32285AA000 499705404 SEAT • Used for removing side bearing race. • Used with PULLER ASSY (499705401). • For VA-type. ST-499705404 499705401 PULLER ASSY...
  • Page 87 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 899524100 PULLER SET • Used for removing side bearing cone of differ- ential. • For VA-type. (1) Puller (2) Cap ST-899524100 18759AA000 PULLER ASSY • Used for removing side bearing cone of differ- ential.
  • Page 88 General Description DIFFERENTIALS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 398417700 DRIFT Used for installing side bearing race. (STi model) (This special tool was prepared for the vehicles of 92MY and before.) ST-398417700 18633AA000 WRENCH COMPL • Used for stopping rotation of companion (Newly adopted tool) flange when loosening and tightening self-lock nut.
  • Page 89 Differential Gear Oil DIFFERENTIALS 2. Differential Gear Oil B: REPLACEMENT 1) Jack-up the vehicle and support it with sturdy A: INSPECTION racks. 1) Disconnect the oil temperature switch connector 2) Disconnect the oil temperature switch connector (Mechanical LSD model). (Mechanical LSD model). DI-00344 DI-00344 (A) Connector...
  • Page 90 Differential Gear Oil DIFFERENTIALS 5) Fill the differential carrier with gear oil to the up- per plug level. NOTE: Carefully refill oil while watching the level. Excess or insufficient oil must be avoided. Oil capacity: Except for STi model: 0.8 2 (0.8 US qt, 0.7 Imp qt) STi model: 0.9 2 —...
  • Page 91 Front Differential DIFFERENTIALS 3. Front Differential A: NOTE 1. AT MODEL For front differential of automatic transmission, re- fer to “AT” section. <Ref. to 4AT-114, Front Differ- ential.> 2. MT MODEL For front differential of manual transmission, refer to “5MT” or “6MT” section. <Ref. to 5MT-102, Front Differential Assembly.>...
  • Page 92 Rear Differential for T-type DIFFERENTIALS 4. Rear Differential for T-type 13) Remove the clamps and bracket of parking brake cable. A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Move the select lever or gear shift lever to “N”. 4) Release the parking brake.
  • Page 93 Rear Differential for T-type DIFFERENTIALS 16) Remove the lower bracket. NOTE: Support the front member with use of a helper to prevent it from dropping. DI-00122 (A) Lower bracket DI-00057 17) Support the rear differential with transmission (A) Bolt A jack.
  • Page 94 Rear Differential for T-type DIFFERENTIALS • When removing the air breather cap, replace the NOTE: air breather cap with a new one. When installing the rear differential front member, do not confuse the installation sequence of the up- per and lower stoppers. 3) Install the DOJ of drive shaft into rear differential.
  • Page 95 Rear Differential for T-type DIFFERENTIALS ST 398457700 ATTACHMENT ST 18759AA000 PULLER ASSY DI-00064 DI-00316 6) Pull out the differential case assembly from dif- 9) Remove the crown gear by loosening the crown ferential carrier. gear bolts. NOTE: Be careful not to hit the teeth against the case. DI-00068 10) Drive out the pinion shaft lock pin from crown DI-00065...
  • Page 96 Rear Differential for T-type DIFFERENTIALS ST 398467700 DRIFT NOTE: The gears as well as thrust washers should be marked or kept separated right and left, front and rear. DI-00073 15) Remove the rear bearing cone from drive pin- ion by supporting the cone with ST. DI-00238 NOTE: Place the replacer so that its center-recessed side...
  • Page 97 Rear Differential for T-type DIFFERENTIALS 17) Remove the pilot bearing together with front ST 398217700 ATTACHMENT bearing cone and spacer using ST. ST 398467700 DRIFT DI-00061 2) Drain the gear oil by removing the plug. DI-00076 3) Remove the air breather cap. NOTE: (A) Pilot bearing •...
  • Page 98 Rear Differential for T-type DIFFERENTIALS 5) Make right and left side bearing retainers in or- 8) Extract the bearing cone with ST. der to identify them at reassembly. Remove the NOTE: side bearing retainer attaching bolts, set the ST to •...
  • Page 99 Rear Differential for T-type DIFFERENTIALS 11) Extract the companion flange with a puller. 14) Remove the front oil seal from differential carri- er using ST. ST 398527700 PULLER ASSY DI-00072 12) Press the end of drive pinion shaft and extract it DI-00075 together with the rear bearing cone, preload adjust- ing spacer and washer.
  • Page 100 Rear Differential for T-type DIFFERENTIALS D: ASSEMBLY ST2 398477703 DRIFT 2 (3) Insert the ST1 into carrier with pinion height 1. EXCEPT FOR STi MODEL adjusting washer and rear bearing cone fitted onto it. NOTE: NOTE: • Assemble in the reverse order of disassembling. •...
  • Page 101 Rear Differential for T-type DIFFERENTIALS ST1 398507702 DUMMY SHAFT Part No. Length mm (in) ST2 398507704 BLOCK 383695201 56.2 (2.213) 383695202 56.4 (2.220) Tightening torque: Preload adjusting 383695203 56.6 (2.228) 181 N·m (18.5 kgf-m, 134 ft-lb) spacer 383695204 56.8 (2.236) 383695205 57.0 (2.244) 383695206...
  • Page 102 Rear Differential for T-type DIFFERENTIALS ST1 398507702 DUMMY SHAFT Pinion height adjusting shim ST2 398507701 DIFFERENTIAL CARRIER Part No. Thickness mm (in) GAUGE 383635200 3.51 (0.1382) 383645200 3.54 (0.1394) 383655200 3.57 (0.1406) 383665200 3.60 (0.1417) 383675200 3.63 (0.1429) 383685200 3.66 (0.1441) 3) Install the selected pinion height adjusting shim on drive pinion, and press the rear bearing cone into position with ST.
  • Page 103 Rear Differential for T-type DIFFERENTIALS ST1 398507703 DUMMY COLLAR ST2 399780104 WEIGHT ST2 399780104 WEIGHT ST3 899580100 INSTALLER DI-00090 9) Install a new self-locking nut. Then tighten it with DI-00087 the ST. ST 498427200 FLANGE WRENCH 6) Insert the spacer, then press-fit the pilot bearing with ST1 and ST2.
  • Page 104 Rear Differential for T-type DIFFERENTIALS • Insert the pinion mate shaft into the differential NOTE: case by aligning the lock pin holes. Before installing the bolts, apply Lock Tite to bolt threads. Lock Tite: THREE BOND 1324 (Part No. 004403042) or equivalent NOTE: Tighten diagonally while tapping the bolt heads.
  • Page 105 Rear Differential for T-type DIFFERENTIALS (2) Install the differential case assembly into dif- Lock Tite: ferential carrier in the reverse order of disas- THREE BOND 1105 (Part No.004403010) or sembly. equivalent Tightening torque: 10.3 N·m (1.05 kgf-m, 7.6 ft-lb) DI-00065 (3) Install the side retainer shims and O-rings to the right and left retainers from which they were DI-00098...
  • Page 106 Rear Differential for T-type DIFFERENTIALS Backlash: • Correct tooth contact 0.10 — 0.20 mm (0.0039 — 0.0079 in) Checking item: Tooth contact pattern is slightly shifted toward to toe side under no-load rotation. (When loaded, contact pattern moves toward heel) DI-00099 16) Check the crown gear runout on its back sur- face, and make sure that pinion and crown gear ro-...
  • Page 107 Rear Differential for T-type DIFFERENTIALS • Flank contact Corrective action: Reduce thickness of drive pinion height adjusting shim in order to move drive pinion Checking item: Backlash is too small. away from crown gear. Contact pattern AT-00213 AT-00209 • Heel contact (Outside end contact) Corrective action: Reduce thickness of drive pinion height adjusting shim in order to move drive pinion Checking item: Contact area is small.
  • Page 108 Rear Differential for T-type DIFFERENTIALS 20) Align the arrow mark on differential carrier with 2. STi MODEL the mark on side retainer during installation. 1) Precautions for assembling • Assemble in the reverse order of disassembling. • Check and adjust each part during assembly. •...
  • Page 109 Rear Differential for T-type DIFFERENTIALS ST 398477702 DRIFT (Example of calculation) T1 = 3.30, T2 = +2, T3 = −1 T = 3.30 + {(2 x 0.01) − (−1 x 0.01)} = 3.33 Result: Thickness = 3.33 mm Therefore use the shim 38336AA310. Pinion height adjusting shim Part No.
  • Page 110 Rear Differential for T-type DIFFERENTIALS 6) Insert the drive pinion into differential carrier, in- 9) Install the self-locking nut. Then tighten it with stall the previously selected bearing preload adjust- the ST. ing spacer and washer. ST (MODEL WITH MECHANICAL LSD) 18633AA000 WRENCH COMPL ST (MODEL WITHOUT MECHANICAL LSD)
  • Page 111 Rear Differential for T-type DIFFERENTIALS 13) Extract the companion flange with a puller. Part No. Thickness mm (in) 383705200 2.59 (0.1020) 383715200 2.57 (0.1012) 383725200 2.55 (0.1004) 383735200 2.53 (0.0996) 383745200 2.51 (0.0988) 383755200 2.49 (0.0980) 383765200 2.47 (0.0972) Preload adjusting washer 383775200 2.45 (0.0965)
  • Page 112 Rear Differential for T-type DIFFERENTIALS ST (MODEL WITH MECHANICAL 19) Assembling side retainer. LSD)18633AA000 (1) Press-fit the side bearing outer race with WRENCH COMPL press and ST. ST (MODEL WITHOUT MECHANICAL LSD) ST 398417700 DRIFT 498427200 FLANGE WRENCH DI-00324 (2) Install the oil seal. <Ref. to DI-71, RE- DI-00071 PLACEMENT, Rear Differential Side Oil Seal.>...
  • Page 113 Rear Differential for T-type DIFFERENTIALS (7) At the same time, measure the total preload NOTE: of drive pinion. Compared with the resistance Be careful that side bearing outer race is not dam- when differential case is not installed, if the total aged by bearing roller.
  • Page 114 Rear Differential for T-type DIFFERENTIALS (2) When the contact pattern is incorrect, read- • Flank contact just according to the instructions given in Checking item: Backlash is too small. “TOOTH CONTACT PATTERN”. Contact pattern NOTE: Be sure to wipe off red lead completely after adjust- ment is completed.
  • Page 115 Rear Differential for T-type DIFFERENTIALS Corrective action: Reduce thickness of drive pinion 26) Align the arrow mark on differential carrier with height adjusting shim in order to move drive pinion the mark on side retainer during installation. away from crown gear. DI-00097 AT-00213 (A) Arrow mark...
  • Page 116 Rear Differential for T-type DIFFERENTIALS E: INSPECTION If the side gear backlash is not within the specifica- tion, adjust clearance as specified by selecting the Wash all the disassembled parts clean, and exam- side gear thrust washer. ine them for wear, damage, or other defects. Re- pair or replace defective parts as necessary.
  • Page 117 Rear Differential for T-type DIFFERENTIALS 4. TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION Inspect the tooth contact between crown gear and driven pinion. <Ref. to DI-36, ASSEMBLY, Rear Differential for T-type.> 5. TOTAL PRELOAD Using a gauge, check the turning resistance in- crease.
  • Page 118 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 119 DIFFERENTIALS Page General Description ..................2 Differential Gear Oil...................25 Front Differential..................27 Rear Differential for T-type................28 Rear Differential for VA-type ..............54 Rear Differential Front Oil Seal ..............69 Rear Differential Side Oil Seal ..............71 Rear Differential Member ................76 General Diagnostic Table................77...
  • Page 120 Rear Differential for VA-type DIFFERENTIALS 5. Rear Differential for VA-type 12) Remove the clamps and bracket of parking brake cable. A: REMOVAL 1) Set the vehicle on a lift. 2) Disconnect the ground cable from battery. 3) Move the select lever or gear shift lever to “N”. 4) Release the parking brake.
  • Page 121 Rear Differential for VA-type DIFFERENTIALS 15) Remove the lower bracket. NOTE: Support the front member with use of a helper to prevent it from dropping. DI-00122 (A) Lower bracket DI-00057 16) Support the rear differential with transmission (A) Bolt A jack.
  • Page 122 Rear Differential for VA-type DIFFERENTIALS 2) Install the DOJ of rear drive shaft into rear differ- 4) Replace the air breather cap. ential. <Ref. to DI-71, REPLACEMENT, Rear Dif- NOTE: ferential Side Oil Seal.> Do not attempt to replace the air breather cap un- ST 28099PA090 SIDE OIL SEAL PROTEC- less necessary.
  • Page 123 Rear Differential for VA-type DIFFERENTIALS ST1 899524100 PULLER SET NOTE: ST2 399520105 SEAT Be careful not to hit the teeth against the case. DI-00137 DI-00134 11) Remove the crown gear by loosening the 8) Remove the bearing race from right and left crown gear bolts.
  • Page 124 Rear Differential for VA-type DIFFERENTIALS NOTE: NOTE: The gears as well as thrust washers should be Hold the drive pinion so as not to drop it. marked or kept separated right and left, front and ST 398467700 DRIFT rear. DI-00073 DI-00238 17) Remove the rear bearing cone from drive pin- ion by supporting the cone with ST.
  • Page 125 Rear Differential for VA-type DIFFERENTIALS ST 398467700 DRIFT • Replace the oil seal with a new one at every dis- assembly. Apply chassis grease between the lips when installing the oil seal. DI-00076 (A) Pilot bearing DI-00078 (B) Spacer 1) Adjust the preload for front and rear bearings. (C) Front bearing Adjust the bearing preload with spacer and washer (D) Rear bearing cup...
  • Page 126 Rear Differential for VA-type DIFFERENTIALS (6) Then install the preload adjusting spacer Tightening torque: and washer, front bearing cone, ST2, compan- 191 N·m (19.5 kgf-m, 141 ft-lb) ion flange, and washer and self-locking nut. ST1 498447150 DUMMY SHAFT ST2 32285AA000 DUMMY COLLAR DI-00081 Front and rear bearing preload DI-00080...
  • Page 127 Rear Differential for VA-type DIFFERENTIALS 2) Adjusting drive pinion height (3) Obtain the thickness of pinion height adjust- ing shim to be inserted from the following formu- Adjust the drive pinion height with shim installed between the rear bearing cone and back of pinion la, and replace the temporarily installed shim with this one.
  • Page 128 Rear Differential for VA-type DIFFERENTIALS 4) Insert the drive pinion into differential carrier, in- • Apply grease between the oil seal lips. stall the previously selected bearing preload adjust- ST 498447120 INSTALLER ing spacer and washer. DI-00089 DI-00156 8) Press-fit the companion flange with ST1 and ST2.
  • Page 129 Rear Differential for VA-type DIFFERENTIALS • Insert the pinion mate shaft into the differential 11) Install the crown gear on differential case. case by aligning the lock pin holes. NOTE: Before installing the bolts, apply Lock Tite to bolt threads. Lock Tite: THREE BOND 1324 (Part No.
  • Page 130 Rear Differential for VA-type DIFFERENTIALS ST 398477702 BEARING OUTER RACE ST 499785500 WRENCH DRIFT CAUTION: Make sure that the oil seal, bearing outer race and cone are properly assembled. DI-00133 (3) Back off the side (left-side) holder approx. 1 1/2 teeth of holder, and tighten the left-side hold- er by approx.
  • Page 131 Rear Differential for VA-type DIFFERENTIALS Backlash: Backlash: 0.10 — 0.15 mm (0.0039 — 0.0059 in) 0.10 — 0.15 mm (0.0039 — 0.0059 in) DI-00172 DI-00172 15) Draw a matching mark on both differential car- 18) Check the crown gear runout on its back sur- rier and holder.
  • Page 132 Rear Differential for VA-type DIFFERENTIALS • Correct tooth contact • Flank contact Checking item: Tooth contact pattern is slightly Checking item: Backlash is too small. shifted toward to toe side under no-load Contact pattern rotation. (When loaded, contact pattern moves toward heel) AT-00209 Corrective action: Reduce thickness of drive pinion...
  • Page 133 Rear Differential for VA-type DIFFERENTIALS Corrective action: Reduce thickness of drive pinion Tightening torque: height adjusting shim in order to move drive pinion 25 N·m (2.5 kgf-m, 18.1 ft-lb) away from crown gear. DI-00189 AT-00213 (A) Rear cover • Heel contact (Outside end contact) Checking item: Contact area is small.
  • Page 134 Rear Differential for VA-type DIFFERENTIALS 1. SIDE GEAR BACKLASH If the crown gear runout exceeds 0.05 mm (0.0020 in), replace the crown gear. Using a dial gauge, check the backlash of the side gear. Side gear backlash: 0.05 — 0.15 mm (0.0020 — 0.0059 in) If the side gear backlash is not within the specifica- tion, adjust the side gear backlash as specified by selecting the side gear thrust washer.
  • Page 135 Rear Differential Front Oil Seal DIFFERENTIALS 6. Rear Differential Front Oil 10) Remove the tank cover. Seal A: REPLACEMENT 1) Disconnect the ground cable from battery. 2) Move the select lever or gear shift lever to “N”. 3) Release the parking brake. 4) Remove the oil drain plug, and drain the gear oil.
  • Page 136 Rear Differential Front Oil Seal DIFFERENTIALS 14) Install the companion flange. NOTE: Use a plastic hammer to install the companion flange. 15) Tighten the self-locking nut within the specified torque range so that the preload of companion flange becomes the same as that before replacing oil seal.
  • Page 137 Rear Differential Side Oil Seal DIFFERENTIALS 7. Rear Differential Side Oil Seal (2) Remove the ABS wheel speed sensor cable clamp from trailing link. A: INSPECTION Make sure that there is no oil leakage from side oil seal. If there is any oil leakage, replace the oil seal. B: REPLACEMENT 1.
  • Page 138 Rear Differential Side Oil Seal DIFFERENTIALS (6) Remove the bolts which secure the front 9) Suspend the rear drive shaft to the rear cross- and rear lateral link to rear housing. member using wire. DI-00205 DI-00053 10) Remove the oil seal using ST. (7) Remove the DOJ from the rear differential by using ST.
  • Page 139 Rear Differential Side Oil Seal DIFFERENTIALS ST 28099PA090 SIDE OIL SEAL PROTEC- (1) Remove the ABS wheel speed sensor cable clamp and parking brake cable clamp from bracket. DI-00325 DI-00200 (2) Install the spline shaft until the spline portion is inside the side oil seal using ST. (A) ABS wheel speed sensor cable clamp ST 28099PA090 SIDE OIL SEAL PROTEC- (B) Parking brake cable clamp...
  • Page 140 Rear Differential Side Oil Seal DIFFERENTIALS (4) Remove the rear stabilizer link. • The side spline shaft circlip comes out together with the shaft. DI-00203 (5) Remove the bolts which secure the trailing link to housing. DI-00218 DI-00204 (A) Tire lever (6) Remove the bolts which secure the front (B) Axle shaft holder and rear lateral link to rear housing.
  • Page 141 Rear Differential Side Oil Seal DIFFERENTIALS 11) Drive in a new side oil seal using ST. NOTE: Make sure that the oil seal lip is not folded over in- NOTE: ward. Apply chassis grease between the oil seal lips. ST 498447100 OIL SEAL INSTALLER DI-00224 DI-00221...
  • Page 142 Rear Differential Member DIFFERENTIALS 8. Rear Differential Member 2) Insert the DOJ of rear drive shaft into rear differ- ential. <Ref. to DI-71, REPLACEMENT, Rear Dif- A: REMOVAL ferential Side Oil Seal.> 1) Set the vehicle on a lift. NOTE: 2) Disconnect the ground cable from battery.
  • Page 143 General Diagnostic Table DIFFERENTIALS 9. General Diagnostic Table A: INSPECTION Symptom or trouble Possible cause Remedy 1. Oil leakage (1) Worn, scratched, or incorrectly seated Repair or replace. front or side oil seal. Scored, battered, or excessively worn sliding surface of com- panion flange.
  • Page 144 General Diagnostic Table DIFFERENTIALS Symptom or trouble Possible cause Remedy 6. Gear noises (1) Improper tooth contact of hypoid gear. Readjust or replace the hypoid gear set. NOTE: (2) Improper backlash for hypoid gear. Readjust. Since noises from engine, muffler, trans- (3) Scored or chipped teeth of hypoid Replace the hypoid gear set.
  • Page 145 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 146 TRANSFER CASE Page General Description ..................2 Transfer Case and Extension Case Assembly..........3 Transfer Clutch....................4 Extension Case ...................5 Oil Seal......................6 Transfer Drive Gear ..................7 Transfer Driven Gear ..................8 Reduction Drive Gear..................9 Reduction Driven Gear................10 Center Differential ..................11 Transfer Clutch Pressure Test ..............12 Transfer Duty Solenoid and Valve Body ...........13...
  • Page 147 General Description TRANSFER CASE 1. General Description A: NOTE For general description, refer to “4AT”, “5MT” or “6MT” section. 4AT model: <Ref. to 4AT-2, General Description.> 5MT model: <Ref. to 5MT-2, General Description.> 6MT model: <Ref. to 6MT-2, General Description.> TC-2...
  • Page 148 Transfer Case and Extension Case Assembly TRANSFER CASE 2. Transfer Case and Extension Case Assembly A: NOTE For removal, installation and inspection work, refer to “5MT” or “6MT” section. 5MT model: <Ref. to 5MT-53, Transfer Case and Extension Case Assembly.> 6MT model: <Ref.

  • Page 149: Transfer Clutch

    Transfer Clutch TRANSFER CASE 3. Transfer Clutch A: NOTE For removal, installation and inspection work, refer to “4AT” section. <Ref. to 4AT-85, Transfer Clutch.> TC-4...

  • Page 150: Extension Case

    Extension Case TRANSFER CASE 4. Extension Case A: NOTE For removal, installation and inspection work, refer to “4AT” section. <Ref. to 4AT-81, Extension Case.> TC-5...
  • Page 151 Oil Seal TRANSFER CASE 5. Oil Seal A: NOTE For removal, installation and inspection work, refer to “4AT”, “5MT” or “6MT” section. 4AT model: <Ref. to 4AT-50, Extension Case Oil Seal.> 5MT model: <Ref. to 5MT-47, Oil Seal.> 6MT model: <Ref.
  • Page 152 Transfer Drive Gear TRANSFER CASE 6. Transfer Drive Gear A: NOTE For removal, installation and inspection work, refer to “5MT” or “6MT” section. 5MT model: <Ref. to 5MT-58, Transfer Drive Gear.> 6MT model: <Ref. to 6MT-57, Transfer Drive Gear.> TC-7...
  • Page 153 Transfer Driven Gear TRANSFER CASE 7. Transfer Driven Gear A: NOTE For removal, installation and inspection work, refer to “5MT” or “6MT” section. 5MT model: <Ref. to 5MT-60, Transfer Driven Gear.> 6MT model: <Ref. to 6MT-59, Transfer Driven Gear.> TC-8...

  • Page 154: Reduction Drive Gear

    Reduction Drive Gear TRANSFER CASE 8. Reduction Drive Gear A: NOTE For removal, installation and inspection work, refer to “4AT” section. <Ref. to 4AT-95, Reduction Drive Gear.> TC-9...

  • Page 155: Reduction Driven Gear

    Reduction Driven Gear TRANSFER CASE 9. Reduction Driven Gear A: NOTE For removal, installation and inspection work, refer to “4AT” section. <Ref. to 4AT-93, Reduction Driv- en Gear.> TC-10...
  • Page 156 Center Differential TRANSFER CASE 10.Center Differential A: NOTE For removal, installation and inspection work, refer to “5MT” or “6MT” section. 5MT model: <Ref. to 5MT-62, Center Differential.> 6MT model: <Ref. to 6MT-61, Center Differential.> TC-11...
  • Page 157 Transfer Clutch Pressure Test TRANSFER CASE 11.Transfer Clutch Pressure Test A: NOTE For inspection work, refer to “4AT” section. <Ref. to 4AT-39, Transfer Clutch Pressure Test.> TC-12...
  • Page 158 Transfer Duty Solenoid and Valve Body TRANSFER CASE 12.Transfer Duty Solenoid and Valve Body A: NOTE For removal, installation and inspection work, refer to “4AT” section. <Ref. to 4AT-70, Transfer Duty Solenoid and Valve Body.> TC-13...
  • Page 159 Transfer Duty Solenoid and Valve Body TRANSFER CASE TC-14...
  • Page 160 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 161 DRIVE SHAFT SYSTEM Page General Description ..................2 Propeller Shaft ..................16 Front Axle....................19 Rear Axle [AWD Model] ................25 Rear Axle [FWD Model] ................33 Front Drive Shaft ..................36 Rear Drive Shaft..................44 General Diagnostic Table................50...
  • Page 162 General Description DRIVE SHAFT SYSTEM 1. General Description A: SPECIFICATIONS 1. PROPELLER SHAFT Turbo (except STi (model STi (model Model Non-turbo for STi) without DCCD) with DCCD) Propeller shaft type ― Front propeller shaft Joint-to-joint length: 584 (22.99) 579 (22.79) mm (in) 643 (25.32) 638 (25.12)
  • Page 163 General Description DRIVE SHAFT SYSTEM 2. FRONT DRIVE SHAFT ASSEMBLY Axle diameter φ D Model Type of drive shaft Axle length L mm (in) mm (in) Non-turbo, Turbo AT EBJ87+PTJ82 26 (1.02) 338.8 (13.34) Sedan Turbo MT (except STi) EBJ87+PTJ82 28 (1.10) 338.8 (13.34) Turbo MT (STi)
  • Page 164 General Description DRIVE SHAFT SYSTEM 3. REAR DRIVE SHAFT ASSEMBLY No. of identification φ D mm (in) Size Model L1 mm (in) protrusion on shaft EBJ82+DOJ82 363 (14.29) 24 (0.94) Sedan turbo (except for STi) EBJ82+DOJ82 353 (13.90) 24 (0.94) BJ79+DOJ79 368 (14.49) 23 (0.91)
  • Page 165 General Description DRIVE SHAFT SYSTEM EBJ82+DOJ82 sedan RH BJ79+DOJ79 sedan R152R/L BJ79+DOJ79 wagon R160RH EBJ82+DOJ82 sedan LH BJ79+DOJ79 wagon R152R/L BJ79+DOJ79 wagon R160LH BJ79+DOJ79 sedan R160RH EBJ82+DOJ82 wagon RH Identification protrusion BJ79+DOJ79 sedan R160LH EBJ82+DOJ82 wagon LH BJ87+DOJ87 R180 RH/LH B: COMPONENT 1.
  • Page 166 General Description DRIVE SHAFT SYSTEM 2. FRONT AXLE • EBJ+PTJ type (10) (11) (12) (13) (19) (14) (15) (16) (21) (17) (18) (20) DS-00274 Circlip Boot (PTJ) (17) Housing Baffle plate (PTJ) (10) Boot (EBJ) (18) Oil seal (OUT) Outer race (PTJ) (11) EBJ ASSY (19)
  • Page 167 General Description DRIVE SHAFT SYSTEM • BJ+DOJ type (22) (10) (11) (12) (13) (19) (14) (15) (16) (21) (17) (18) (20) DS-00287 Circlip (10) Boot (EBJ) (19) Hub bolt Baffle plate (11) EBJ ASSY (20) Outer race (PTJ) (12) Tone wheel (with ABS) (21) Axle nut Snap ring...

  • Page 168: Rear Axle

    General Description DRIVE SHAFT SYSTEM 3. REAR AXLE • AWD model (10) (11) (14) (12) (15) (13) (21) (17) (16) (18) (19) (20) (23) (22) DS-00222 Circlip (11) Boot (20) Tone wheel Baffle plate (DOJ) (12) Non-turbo: BJ ASSY (21) Hub bolt Outer race (DOJ) Turbo: EBJ ASSY...
  • Page 169 General Description DRIVE SHAFT SYSTEM • FWD model DS-00275 Rear spindle Washer Tightening torque: N·m (kgf-m, ft-lb) Tone wheel Axle nut T1: 6 (0.6, 4.4) Hub bolt O-ring T2: 190 (19.4, 140) Hub cap DS-9...
  • Page 170 General Description DRIVE SHAFT SYSTEM C: CAUTION • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease etc. with that of another • Wear working clothing, including a cap, protec- grade or from other manufacturers. tive goggles and protective shoes during operation.
  • Page 171 General Description DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 926470000 AXLE SHAFT Used for removing axle shaft. PULLER ST-926470000 927060000 HUB REMOVER • Used for removing front hub. • Used with HUB STAND (927080000). ST-927060000 927420000 HUB REMOVER • Used for removing rear hub. •...
  • Page 172 General Description DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927100000 BEARING PULLER • Used for disassembling and assembling front housing bearing. • Used with HOUSING STAND (927400000). ST-927100000 927140000 AXLE SHAFT Same as plate 2 included in AXLE SHAFT PULLER PLATE PULLER (926470000).
  • Page 173 General Description DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927410000 OIL SEAL • Used for installing oil seal into front housing. INSTALLER • Used with HOUSING STAND (927400000). ST-927410000 927430000 HOUSING STAND • Used for disassembling and assembling rear housing bearing.
  • Page 174 General Description DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927460000 OIL SEAL • Used for installing outer oil seal. INSTALLER • Used with HOUSING STAND (927430000). ST-927460000 927450000 HUB INSTALLER • Used for pressing hub bearing into hub. • Used with HUB STAND (927080000). ST-927450000 28099PA090 OIL SEAL PROTEC-...
  • Page 175 General Description DRIVE SHAFT SYSTEM ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 28099PA100 DRIVE SHAFT Used for removing rear drive shaft from rear dif- REMOVER ferential. ST28099PA100 28099AC000 BOOT BAND PLI- Used for tightening front BJ boot band. ST28099AC000 2. GENERAL PURPOSE TOOLS TOOL NAME REMARKS Puller...
  • Page 176 Propeller Shaft DRIVE SHAFT SYSTEM 2. Propeller Shaft 8) Make matching marks on affected parts before removal. A: REMOVAL NOTE: • Before removing the propeller shaft, wrap the metal parts with a cloth or rubber material. • In case of DOJ type, before removing the propel- ler shaft, wrap the metal parts (installed at the rub- ber boot of center DOJ) with a cloth or rubber material, as shown in the figure.
  • Page 177 Propeller Shaft DRIVE SHAFT SYSTEM 13) Install the extension cap to transmission. (1) Temporarily tighten the bolt (A) while push- ing cover forward. NOTE: (2) Tighten the bolt (B) to specified torque. If the extension cap is not available, place a vinyl (3) Tighten the bolt (A) to specified torque.
  • Page 178 Propeller Shaft DRIVE SHAFT SYSTEM 2. SPLINES AND BEARING LOCATIONS 4. CENTER BEARING FREE PLAY 1) Remove the center exhaust pipes. 1) Remove the front and center exhaust pipes. 2) Remove the rear exhaust pipe and muffler. 2) Remove the rear exhaust pipe and muffler. 3) Remove the heat shield cover.
  • Page 179 Front Axle DRIVE SHAFT SYSTEM 3. Front Axle 6) Remove the disc rotor from hub. NOTE: A: REMOVAL If the disc rotor seizes up within hub, drive disc rotor 1) Lift-up the vehicle and remove the front wheels. out by installing an 8-mm bolt in screw hole on ro- 2) Unlock the axle nut.
  • Page 180 Front Axle DRIVE SHAFT SYSTEM 9) Remove the ABS wheel speed sensor assembly 12) After scribing an alignment mark on the camber and harness. adjusting bolt head, remove the bolts which con- nect the housing and strut, and disconnect the housing from strut.
  • Page 181 Front Axle DRIVE SHAFT SYSTEM 9) Install the disc brake caliper on housing. C: DISASSEMBLY 1) Using the ST1, support the housing and hub se- Tightening torque: curely. 80 N·m (8.2 kgf-m, 59 ft-lb) 2) Attach the ST2 to housing and drive the hub out. 10) Connect the stabilizer link.
  • Page 182 Front Axle DRIVE SHAFT SYSTEM 3) Remove the disc cover from housing. 8) Using the ST and a hydraulic press, drive the hub bolts out. ST 927080000 HUB STAND DS-00051 4) Using a standard screwdriver, remove the outer DS-00054 and inner oil seals. 5) Using a flat tip screwdriver, remove the snap D: ASSEMBLY ring.
  • Page 183 Front Axle DRIVE SHAFT SYSTEM • Be careful not to remove the plastic lock from in- 8) Invert the ST and housing. ner race when installing the bearing. ST 927400000 HOUSING STAND 9) Apply sufficient grease to the oil seal lip. Specified grease: SHELL 6459N NOTE:...
  • Page 184 Front Axle DRIVE SHAFT SYSTEM Limit: Maximum: 0.05 mm (0.0020 in) DS-00062 DS-24...
  • Page 185 Rear Axle [AWD Model] DRIVE SHAFT SYSTEM 4. Rear Axle [AWD Model] 8) Disconnect the parking brake cable end. A: REMOVAL 1. DISC BRAKE 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and remove the rear wheel. 3) Unlock the axle nut.
  • Page 186 Rear Axle [AWD Model] DRIVE SHAFT SYSTEM 12) Remove the rear ABS wheel speed sensor 2. DRUM BRAKE from back plate. 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and remove the rear wheel cap and wheels. 3) Unlock the axle nut.
  • Page 187 Rear Axle [AWD Model] DRIVE SHAFT SYSTEM 11) Disconnect the rear stabilizer from rear lateral NOTE: link. Remove the bolts which secure the trailing link If the brake drum is difficult to remove, drive it out assembly to rear housing. by installing two 8-mm bolts into bolt hole in brake drum.
  • Page 188 Rear Axle [AWD Model] DRIVE SHAFT SYSTEM • When the rear drive shaft is to be replaced, 5) Using a new self-locking nut, temporarily tighten also replace the inner oil seal with a new one. the rear housing assembly and trailing link assem- bly.
  • Page 189 Rear Axle [AWD Model] DRIVE SHAFT SYSTEM 13) Install rear ABS wheel speed sensor. 5) Using a new self-locking nut, temporarily tighten the rear housing assembly and trailing link assem- bly. ( 1 ) DS-00069 (1) ABS wheel speed sensor DS-00066 6) Tighten the rear housing assembly and strut as- 14) Install the wheel and tighten the wheel nuts to...
  • Page 190 Rear Axle [AWD Model] DRIVE SHAFT SYSTEM 15) Connect the rear ABS wheel speed sensor to 4) Using a flat tip screwdriver, remove the snap back plate. ring. NOTE: Be careful not to damage the housing at removal. ( 1 ) DS-00069 (1) ABS wheel speed sensor DS-00089...
  • Page 191 Rear Axle [AWD Model] DRIVE SHAFT SYSTEM D: ASSEMBLY • Be careful not to remove the plastic lock from in- ner race when installing the bearing. NOTE: When the hub is to be removed from housing, re- place the bearing set and oil seal with new ones. 1) Using the ST, press the new hub bolt into place.
  • Page 192 Rear Axle [AWD Model] DRIVE SHAFT SYSTEM ST2 927460000 OIL SEAL INSTALLER E: INSPECTION 1) Moving the rear tire up and down by hand, check there is no backlash in bearing, and check the wheel rotates smoothly. DS-00097 8) Using the ST1 and ST2, press the sub seal into place.
  • Page 193 Rear Axle [FWD Model] DRIVE SHAFT SYSTEM 5. Rear Axle [FWD Model] CAUTION: Do not reuse the self-locking nut. A: REMOVAL CAUTION: Remove the axle nut with vehicle weight not ap- plied on axle. Failure to follow this rule may damage the wheel bearings.
  • Page 194 Rear Axle [FWD Model] DRIVE SHAFT SYSTEM 4) Clean the brake pipe connection, and then con- 2) Remove the drum brake assembly or parking nect the brake pipe to wheel cylinder using a flare brake assembly from rear spindle. nut wrench. Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) 5) Connect the cable end of parking brake cable.
  • Page 195 Rear Axle [FWD Model] DRIVE SHAFT SYSTEM Limit: Maximum: 0.05 mm (0.0020 in) DS-00062 DS-35...

  • Page 196: Front Drive Shaft

    Front Drive Shaft DRIVE SHAFT SYSTEM 6. Front Drive Shaft NOTE: After pulling out the drive shaft, be sure to replace A: REMOVAL with a new oil seal. 1) Jack-up the vehicle, support it with rigid racks, and then remove the front wheel cap and wheels. 2) Raise the caulking portion of axle nut.
  • Page 197 Front Drive Shaft DRIVE SHAFT SYSTEM Tightening torque: 4) Remove the PTJ outer race from shaft assem- bly. 220 N·m (22.4 kgf-m, 162 ft-lb) 5) Wipe off the grease. CAUTION: • Always tighten the axle nut before installing CAUTION: wheel on vehicle. If the tire is installed and The grease is a special grease.
  • Page 198 Front Drive Shaft DRIVE SHAFT SYSTEM 9) Remove the snap ring and trunnion. CAUTION: The boot must be replaced with a new one whenever it is removed. DS-00209 CAUTION: DS-00113 Be sure to wrap the shaft splines with vinyl tape to prevent the boot from scratches.
  • Page 199 Front Drive Shaft DRIVE SHAFT SYSTEM 3) Apply a coat of specified grease [60 to 70 g (2.12 NOTE: to 2.47 oz)] to EBJ. • The grease is a special grease (grease for con- 4) Apply an even coat of specified grease [20 to 30 stant velocity joint).
  • Page 200 Front Drive Shaft DRIVE SHAFT SYSTEM ST 28099AC000 BOOT BAND PLIER CAUTION: Be careful with the free ring position. DS-00116 (A) Large boot band (B) Boot (C) Torque wrench (D) Socket flex handle (E) EBJ Tightening torque: Large boot band 157 N·m (16.0 kgf-m, 116 ft-lb) or more Small boot band 133 N·m (13.6 kgf-m, 98 ft-lb) or more...
  • Page 201 Front Drive Shaft DRIVE SHAFT SYSTEM 20) Tighten the band by using the ST. 4) Insert the DOJ cage onto shaft. ST 925091000 BAND TIGHTENING TOOL NOTE: Insert the cage with cut-out portion facing the shaft NOTE: end, since the cage has an orientation. Tighten the band until it cannot be moved by hand.
  • Page 202 Front Drive Shaft DRIVE SHAFT SYSTEM 7) Fill 80 to 90 g (2.82 to 3.17 oz) of specified 14) Put a new band through the clip and wind twice grease into the interior of DOJ outer race. in alignment with band groove of boot. 8) Apply a coat of specified grease to cage pocket NOTE: and six balls.
  • Page 203 Front Drive Shaft DRIVE SHAFT SYSTEM E: INSPECTION Check the removed parts for damage, wear, corro- sion etc. If faulty, repair or replace. 1) DOJ (Double Offset Joint) Check seizure, corrosion, damage, wear and ex- cessive play. 2) PTJ (Pillow tripod Joint) Check seizure, corrosion, damage and excessive play.
  • Page 204 Rear Drive Shaft DRIVE SHAFT SYSTEM 7. Rear Drive Shaft 7) Remove the bolts which secure the front lateral link and rear lateral link to housing. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and remove the rear wheel. 3) Unlock the axle nut.
  • Page 205 Rear Drive Shaft DRIVE SHAFT SYSTEM 4) Temporarily tighten the front lateral link and rear NOTE: lateral link to housing using a new self-locking nuts. Fit the ST to the bolt (A) as shown in the figure to avoid damage on the side bearing retainer. DS-00067 5) Temporarily tighten the trailing link to housing using a new self-locking nut.
  • Page 206 Rear Drive Shaft DRIVE SHAFT SYSTEM Tightening torque: CAUTION: 32 N·m (3.3 kgf-m, 24 ft-lb) Make the tires contact the ground fully and the vehicle be in curb weight whenever carrying out the tightening of bush portions. 13) Tighten the installation bolt of rear housing as- sembly and lateral link assembly.
  • Page 207 Rear Drive Shaft DRIVE SHAFT SYSTEM • Disassemble with exercising care not to lose NOTE: balls (6 pcs). Insert the cage with cut-out portion facing the shaft end, since the cage has an orientation. DS-00126 DS-00283 (A) Outer race (B) Grease (A) Cage (B) Cut-out portion 8) To remove the cage from inner race, turn the...
  • Page 208 Rear Drive Shaft DRIVE SHAFT SYSTEM 7) Fill 80 to 90 g (2.82 to 3.17 oz) of specified 14) Put a new band through the clip and wind twice grease into the interior of DOJ outer race. in alignment with band groove of boot. 8) Apply a coat of specified grease to cage pocket NOTE: and six balls.
  • Page 209 Rear Drive Shaft DRIVE SHAFT SYSTEM E: INSPECTION Check the removed parts for damage, wear, corro- sion, etc. If faulty, repair or replace. 1) DOJ (Double Offset Joint) Check seizure, corrosion, damage, wear and ex- cessive play. 2) Shaft Check excessive bending, twisting, damage and wear.
  • Page 210 General Diagnostic Table DRIVE SHAFT SYSTEM 8. General Diagnostic Table A: INSPECTION NOTE: Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper wheel alignment, etc. Symptom Possible cause Corrective action Noise or vibration from propeller shaft Center bearing Check the center bearing.
  • Page 211 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 212 Page General Description ..................2 ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)....6 ABS Sequence Control ................10 Front ABS Wheel Speed Sensor...............13 Rear ABS Wheel Speed Sensor ...............16 Front Tone Wheel ..................19 Rear Tone Wheel ..................20 G Sensor ....................21 Lateral G Sensor ..................23...
  • Page 213 General Description 1. General Description A: SPECIFICATIONS Item Specification or remarks Front 0.3 — 0.8 mm (0.012 — 0.031 in) ABS wheel speed sensor gap Rear 0.7 — 1.2 mm (0.028 — 0.047 in) Front 1.25±0.25 kΩ ABS wheel speed sensor resis- tance Rear 1.15±0.115 kΩ...
  • Page 214 General Description B: COMPONENT 1. SENSOR ABS00210 G sensor Front ABS wheel speed sensor LH Tightening torque: N·m (kgf-m, ft-lb) Front ABS wheel speed sensor T1: 18 (1.8, 13.0) Rear ABS wheel speed sensor T2: 33 (3.3, 24) Adjusting spacer Lateral G sensor (STi model) Rear ABS wheel speed sensor LH ABS-3...
  • Page 215 General Description 2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U) (11) (12) (10) ABS00472 Stud bolt Primary inlet Tightening torque: N·m (kgf-m, ft-lb) Damper Rear-LH outlet T1: 2.65 (0.27, 1.95) ABS control module and hydraulic Rear-RH outlet T2: 18 (1.8, 13.0) control unit (ABSCM&H/U) (10) Bracket...
  • Page 216 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical systems. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical systems. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 2.
  • Page 217 ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) 2. ABS Control Module and Hy- • Do not let water get into the connector. draulic Control Unit (ABSCM&H/U) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the air intake duct from engine com- partment to facilitate removal of ABSCM&H/U.
  • Page 218 ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) C: INSPECTION 6) When the hydraulic unit begins to work, and first the FL side performs decompression, holding, and 1) Check the connected and fixed condition of con- compression, and then the FR side performs de- nector.
  • Page 219 ABS Control Module and Hydraulic Control Unit (ABSCM&H/U) 2. CHECKING THE HYDRAULIC UNIT ABS <Ref. to ABS-10, ABS Sequence Control.> OPERATION WITH BRAKE TESTER 6) Hydraulic unit begins to work; and check the fol- lowing working sequence. 1) In the case of AWD AT models, install a spare (1) The FL wheel performs decompression, fuse with the FWD connector in the main fuse box holding, and compression in sequence, and...
  • Page 220 18) Check that correct information (model year, drive system, transmission type) is displayed on the initial screen by connecting Subaru Select Mon- ABS00449 itor. 19) Start the engine and move the car to accelerate (1) H/U to more than 20 km/h (12.4 MPH).
  • Page 221 1) Turn the ignition switch to OFF. operate. 2) Connect the diagnosis terminal to terminal No. 6 1) Connect the Subaru Select Monitor to data link of the diagnosis connector beside driver’s seat. connector under driver’s seat instrument panel low- er cover.
  • Page 222 ABS Sequence Control 3. CONDITIONS FOR ABS SEQUENCE CONTROL V max < 4 km/h (2.5 MPH) V max < 10 km/h (6 MPH) (17) (28) (18) (29) (30) (29) (19) (19) (19) (19) (20) (20) (20) (21) (31) (22) (32) (30) (32) (30)
  • Page 223 Pressure of master cylinder NOTE: When the Subaru Select Monitor is used, control operation starts at point A. The patterns from IGN key ON to the point A show that operation is started by diagnosis connector. (However, the brake light switch must be ON before point A.)
  • Page 224 Front ABS Wheel Speed Sensor 4. Front ABS Wheel Speed Sen- • Do not pull the sensor harness during remov- A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the front ABS wheel speed sensor connector located next to the front strut mounting house in engine compartment.
  • Page 225 Front ABS Wheel Speed Sensor 3) Check the ABS wheel speed sensor gap. <Ref. Terminal No. Standard to ABS-14, SENSOR GAP, INSPECTION, Front 1 and 2 1.25±0.25 kΩ ABS Wheel Speed Sensor.> After standard clear- ance is obtained, tighten the ABS wheel speed NOTE: sensor on housing to specified torque.
  • Page 226 Front ABS Wheel Speed Sensor 3. OUTPUT VOLTAGE Output voltage can be checked by the following method. Install the resistor and condenser, then ro- tate the wheel about 2.75 km/h (2 MPH) or equiva- lent. Output voltage specification: 0.12 to 1 V (at 20 Hz) NOTE: Regarding terminal No., please refer to item 1.
  • Page 227 Rear ABS Wheel Speed Sensor 5. Rear ABS Wheel Speed Sen- CAUTION: Be careful not to strike the ABS wheel speed sensor’s pole piece against tone wheel and ad- A: REMOVAL jacent metal parts during installation. 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle.
  • Page 228 Rear ABS Wheel Speed Sensor 6) After confirmation of the ABS wheel speed sen- ABS wheel speed sensor clearance: sor clearance, connect the connector to ABS wheel 0.7 — 1.2 mm (0.028 — 0.047 in) speed sensor. 7) Connect the battery ground cable to battery. C: INSPECTION 1.
  • Page 229 Rear ABS Wheel Speed Sensor 3. OUTPUT VOLTAGE Output voltage can be checked by the following method. Install the resistor and condenser, then ro- tate the wheel about 2.75 km/h (2 MPH) or equiva- lent. Output voltage specification: 0.12 — 1 V (at 20 Hz) NOTE: Regarding terminal No., please refer to item 1.
  • Page 230 Front Tone Wheel 6. Front Tone Wheel A: REMOVAL Refer to Front Drive Shaft, because front tone wheel is integrated with front drive shaft. <Ref. to DS-36, REMOVAL, Front Drive Shaft.> B: INSTALLATION Refer to Front Drive Shaft, because front tone wheel is integrated with front drive shaft.
  • Page 231 Rear Tone Wheel 7. Rear Tone Wheel A: REMOVAL Refer to Rear Axle, because the rear tone wheel is installed to rear hub. <Ref. to DS-25, REMOVAL, Rear Axle [AWD Mod- el].> <Ref. to DS-33, REMOVAL, Rear Axle [FWD Model].> B: INSTALLATION Refer to Rear Axle, because the rear tone wheel is installed to rear hub.
  • Page 232 G Sensor 8. G Sensor A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console cover. <Ref. to EI-42, REMOVAL, Console Box.> 3) Disconnect the connector from G sensor. 4) Remove the G sensor from body. CAUTION: •...
  • Page 233 Go to step 6. Replace the G 1)Turn the ignition switch to OFF. 2.3±0.2 V when the vehicle is sensor. 2)Connect the Subaru Select Monitor to data in horizontal position? link connector. 3)Turn the Subaru Select Monitor into {BRAKE CONTROL} mode.
  • Page 234 Lateral G Sensor 9. Lateral G Sensor A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console cover. <Ref. to EI-42, REMOVAL, Console Box.> 3) Disconnect the connector from lateral G sensor. 4) Remove the lateral G sensor from vehicle. CAUTION: Do not drop or bump the lateral G sensor.
  • Page 235 Go to step 6. Replace the lat- 1)Turn the ignition switch to OFF. 2.5±0.2 V when the vehicle is eral G sensor. 2)Connect the Subaru Select Monitor to data in horizontal position? link connector. 3)Turn the Subaru Select Monitor into {BRAKE CONTROL} mode.
  • Page 236 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 237 Basic Diagnostic Procedure ................2 Check List for Interview................4 General Description ..................8 Electrical Components Location..............10 Control Module I/O Signal .................12 Subaru Select Monitor................16 Read Diagnostic Trouble Code (DTC) ............19 Inspection Mode..................20 Clear Memory Mode..................21 ABS Warning Light/Brake Warning Light Illumination Pattern ....22 List of Diagnostic Trouble Code (DTC) .............23...
  • Page 238 Go to step 3. 1)Turn the ignition switch to OFF. 2)Connect the SUBARU SELECT MONITOR to data link connector. 3)Turn the ignition switch to ON and SUBARU SELECT MONITOR to ON. NOTE: If the communication function of Subaru Select Monitor cannot be executed normally, check communication circuit.
  • Page 239 Inspect using Complete the 1)For the DTC list, refer to “List of DTC”. <Ref. play? “diagnostics pro- diagnosis. to ABS(diag)-23, WITH SUBARU SELECT cedure with Sub- MONITOR, LIST, List of Diagnostic Trouble aru Select Code (DTC).> Monitor”. <Ref. to 2)Repair trouble cause.
  • Page 240 Check List for Interview ABS (DIAGNOSTICS) 2. Check List for Interview A: CHECK Check the following items about the vehicle’s state. 1. STATE OF ABS WARNING LIGHT ❏ Always ABS warning light ❏ Sometimes comes on. ❏ Only once ❏ Does not come on •...
  • Page 241 Check List for Interview ABS (DIAGNOSTICS) 2. STATE OF BRAKE WARNING LIGHT ❏ Always Brake warning light ❏ Sometimes comes on. ❏ Only once ❏ Does not come on ❏ When parking brake lever is pulled ❏ When parking brake lever is released •...
  • Page 242 Check List for Interview ABS (DIAGNOSTICS) 3. SYMPTOMS ❏ Does not operate. ABS operating condi- tion ❏ Operates only when abruptly applying brakes. Vehicle speed : km/h • How to step on brake pedal : a) Operating time : b) Operating noise : ❏ Produce / ❏ Does not produce ❏...
  • Page 243 Check List for Interview ABS (DIAGNOSTICS) 4. CONDITIONS UNDER WHICH TROUBLE OCCURS ❏ Fine Environment a) Weather ❏ Cloudy ❏ Rainy ❏ Snowy ❏ Various/Others : °C (°F) b) Ambient temperature ❏ Urban area c) Road ❏ Suburbs ❏ Highway ❏...
  • Page 244 General Description ABS (DIAGNOSTICS) 3. General Description • Rear <Ref. to BR-38, INSPECTION, Rear Brake Pad.> and <Ref. to BR-40, INSPECTION, Rear A: CAUTION Disc Rotor.> or <Ref. to BR-48, INSPECTION, Rear Drum Brake Shoe.> and <Ref. to BR-49, IN- 1.
  • Page 245 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical systems. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical systems. MONITOR KIT ST22771AA030 2. GENERAL PURPOSE TOOLS TOOL NAME REMARKS Circuit tester Used for measuring resistance, voltage and amperage. Oscilloscope Used for measuring sensor.
  • Page 246 Brake & EBD warning light Connector Tone wheel (14) Lateral G sensor (STi model) Diagnosis connector ABS wheel speed sensor ABS warning light Wheel cylinder Data link connector (for Subaru (10) G sensor Select Monitor) (11) Stop light switch ABS(diag)-10...
  • Page 247 Electrical Components Location ABS (DIAGNOSTICS) (13) ABS00101 ABS00337 (10) ABS00102 ABS00106 FRONT ABS00344 ABS00107 REAR (14) ABS00104 ABS00345 ABS(diag)-11...
  • Page 248 Control Module I/O Signal ABS (DIAGNOSTICS) 5. Control Module I/O Signal A: ELECTRICAL SPECIFICATION B301 or 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 27 28 29 30 31 ABS00182 ABS control module and hydraulic Connector switch...
  • Page 249 5.5 V when ABS does not operate. Data is received. 20 — 23 Less than 1.5 V when no data is received. Subaru Select Moni- tor*2 Data is sent. 5 — 23 4.75 — 5.25 V when no data is sent.
  • Page 250 Control Module I/O Signal ABS (DIAGNOSTICS) B: WIRING DIAGRAM (16) (17) (18) (19) (20) (21) (22) (23) (28) (10) (11) (12) (24) (13) (25) (14) (26) (15) (27) ABS00375 Battery (12) Rear inlet solenoid valve LH (23) G sensor (13) Rear outlet solenoid valve LH (24) Front ABS wheel speed sensor LH...
  • Page 251 Control Module I/O Signal ABS (DIAGNOSTICS) C: WAVEFORM 20 Hz : 0.12 20 Hz ABS00034 (1) ABS wheel speed sensor (2) Terminal No. (3) Standard output voltage ABS(diag)-15...
  • Page 252 • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MAN- ABS00112 UAL. 4) Connect the Subaru Select Monitor to data link • For detailed concerning the DTC, refer to the connector. LIST OF DTC. <Ref. to ABS(diag)-23, List of Diag- (1) Data link connector located in the lower por- nostic Trouble Code (DTC).>...
  • Page 253 CCM Signal ABS operation signal from ABS control module to TCM ON or OFF NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. 3. CLEAR MEMORY MODE NOTE: For detailed operation procedure, refer to the SUB- 1) On the «Main Menu»...
  • Page 254 DTC, preceded by a question mark “?”, ap- Subaru Select Monitor display in volts. pears on the Subaru Select Monitor display. This Lateral G sen- Voltage equivalent to Lateral G detected shows it may be an unreliable reading.
  • Page 255 Read Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) 7. Read Diagnostic Trouble Code (DTC) A: OPERATION Refer to SUBARU SELECT MONITOR for informa- tion about how to obtain and understand DTCs. <Ref. to ABS(diag)-16, Subaru Select Monitor.> ABS(diag)-19...
  • Page 256 Inspection Mode ABS (DIAGNOSTICS) 8. Inspection Mode A: OPERATION Reproduce the condition under which the problem has occurred as much as possible. Drive the vehicle at a speed more than 40 km/h (25 MPH) for at least 1 minute. ABS(diag)-20...
  • Page 257 Clear Memory Mode ABS (DIAGNOSTICS) 9. Clear Memory Mode A: OPERATION Refer to SUBARU SELECT MONITOR for informa- tion about how to clear DTC. <Ref. to ABS(diag)- 16, Subaru Select Monitor.> ABS(diag)-21...
  • Page 258 ABS Warning Light/Brake Warning Light Illumination Pattern ABS (DIAGNOSTICS) 10.ABS Warning Light/Brake Warning Light Illumination Pattern A: INSPECTION IG SW ABS00341 START Illuminates Parking brake ABS warning light 1.5 sec. Release Goes out Brake warning light 1) When the ABS warning light does not illuminate in accordance with this illumination pattern, there must be an electrical malfunction.
  • Page 259 List of Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) 11.List of Diagnostic Trouble Code (DTC) A: LIST 1. WITHOUT SUBARU SELECT MONITOR Contents of diagnosis Index No. <Ref. to ABS(diag)-26, ABS WARNING LIGHT DOES NOT COME — ABS warning light does not illuminate.
  • Page 260 List of Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Sub code No. Display screen Contents of diagnosis Index No. Abnormal ABS wheel <Ref. to ABS(diag)-58, DTC 29 ABNORMAL ABS Abnormal ABS wheel 5080 speed sensor signal WHEEL SPEED SENSOR SIGNAL ON ANY ONE OF speed sensor signal 50C0 on any one of four...
  • Page 261 List of Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Sub code No. Display screen Contents of diagnosis Index No. <Ref. to ABS(diag)-85, DTC 52 OPEN CIRCUIT IN Open circuit in motor Open circuit in motor 10A1 MOTOR RELAY CIRCUIT, Diagnostics Procedure with relay circuit relay circuit Diagnostic Trouble Code (DTC).>...
  • Page 262 Diagnostics Procedure without Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) 12.Diagnostics Procedure without Diagnostic Trouble Code (DTC) A: ABS WARNING LIGHT DOES NOT COME ON DIAGNOSIS: • ABS warning light circuit is open or shorted. TROUBLE SYMPTOM: • When the ignition switch is turned to ON (engine OFF), ABS warning light does not come on. WIRING DIAGRAM: LHD MODEL BATTERY...
  • Page 263 Diagnostics Procedure without Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) RHD MODEL BATTERY SBF-3 SBF-1 IGNITION SWITCH No.13 RELAY HOLDER B225 COMBINATION METER ABS RELAY GROUND TERMINAL B264 B200 ABSCM&H/U B264 1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 19 20...
  • Page 264 Diagnostics Procedure without Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK ABS AND BRAKE WARNING LIGHT Is the ABS warning light bulb Replace the ABS Go to step 3. BULB. open? and brake warn- 1)Turn the ignition switch to OFF. ing light bulb.
  • Page 265 Diagnostics Procedure without Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 Go to step 9. Repair open circuit Ω? 1)Turn the ignition switch to OFF. in the ABSCM&H/ 2)Disconnect the connector from ABSCM&H/ U ground harness.
  • Page 266 Diagnostics Procedure without Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) B: ABS WARNING LIGHT DOES NOT GO OFF DIAGNOSIS: • ABS warning light circuit is open or shorted. TROUBLE SYMPTOM: • When starting the engine and while ABS warning light is kept ON. WIRING DIAGRAM: LHD MODEL BATTERY...
  • Page 267 Diagnostics Procedure without Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) RHD MODEL BATTERY SBF-3 SBF-1 IGNITION SWITCH No.13 RELAY HOLDER B225 COMBINATION METER ABS RELAY GROUND TERMINAL B264 B200 ABSCM&H/U B264 1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 19 20...
  • Page 268 Diagnostics Procedure without Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK GROUND TERMINAL. Is the resistance less than 0.5 Go to step 3. Repair the open Ω? Measure the resistance between Ground ter- circuit in Ground minals (B81) and chassis ground. terminal harness.
  • Page 269 Diagnostics Procedure without Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK WIRING HARNESS. Is the resistance less than 0.5 Go to step 11. Repair the har- Ω? Measure the resistance between connector ness. (B37) and chassis ground. Connector & terminal LHD: (B37) No.
  • Page 270 Diagnostics Procedure without Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) C: BRAKE WARNING LIGHT DO NOT GO OFF DIAGNOSIS: • Brake warning light circuit is shorted. • Faulty sensor/connector TROUBLE SYMPTOM: • After starting the engine, brake warning light is kept ON, even if the parking brake lever has been released. WIRING DIAGRAM: LHD MODEL BATTERY...
  • Page 271 Diagnostics Procedure without Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) RHD MODEL BATTERY SBF-4 SBF-1 IGNITION SWITCH PARKING COMBINATION BRAKE/ METER BRAKE FLUID LEVEL WARNING LIGHT : STi KA MODEL DRIVER'S CONTROL : EXCEPT FOR STi KA MODEL CENTER DIFFERENTIAL CONTROL MODULE B289 BRAKE FLUID LEVEL SWITCH...
  • Page 272 Diagnostics Procedure without Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK BRAKE FLUID LEVEL SWITCH. Is the resistance more than 1 Go to step 3. Replace the mas- 1)Disconnect the level switch connector (B16) MΩ? ter cylinder. from master cylinder. 2)Measure the resistance of master cylinder terminals.
  • Page 273 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) 13.Diagnostics Procedure with Diagnostic Trouble Code (DTC) A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE DIAGNOSIS: • Faulty harness connector TROUBLE SYMPTOM: • Communication cannot be executed between ABS and Subaru select monitor. WIRING DIAGRAM: BATTERY GENERATOR B200 IGNITION SWITCH...
  • Page 274 LECT MONITOR. tem displayed on Subaru 1)Turn the ignition switch to ON. Select Monitor? 2)Using the Subaru Select Monitor, check whether communication to other system can be executed normally. CHECK COMMUNICATION OF SUBARU SE- Are the name and year of sys- Replace the Go to step 6.
  • Page 275 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK POWER SUPPLY CIRCUIT. Is the voltage 10 — 15 V? Go to step 11. Repair the open 1)Turn the ignition switch to ON (engine OFF). circuit in harness 2)Measure the ignition power supply voltage between between ABSCM&H/U connector and chassis...
  • Page 276 TROUBLE SYMPTOM: • ABS warning light remains on. • NO DTC displayed on the Subaru Select Monitor. NOTE: When the ABS warning light is OFF and “NO DTC” is displayed on Subaru Select Monitor, the system is in normal condition. ABS(diag)-40...
  • Page 277 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) WIRING DIAGRAM: LHD MODEL BATTERY SBF-3 SBF-1 IGNITION SWITCH No.13 RELAY HOLDER B108 : TURBO ENGINE MODEL NA : NON-TURBO ENGINE B225 MODEL ABS RELAY COMBINATION METER GROUND TERMINAL B264 B100 B301 ABSCM&H/U B264...
  • Page 278 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) RHD MODEL BATTERY SBF-3 SBF-1 IGNITION SWITCH No.13 RELAY HOLDER B225 COMBINATION METER ABS RELAY GROUND TERMINAL B264 B200 ABSCM&H/U B264 1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 19 20...
  • Page 279 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK PROJECTION AT ABSCM&H/U. Is there any damage on projec- Go to step 3. Replace the 1)Turn the ignition switch to OFF. tion which switches connector ABSCM&H/U. 2)Disconnect the connector from ABSCM& switch? <Ref.
  • Page 280 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) F: DTC 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS WHEEL SPEED SEN- SOR CIRCUIT DIAGNOSIS: • Faulty ABS wheel speed sensor (Broken wire, input voltage too high) • Faulty harness connector TROUBLE SYMPTOM: •...
  • Page 281 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) WIRING DIAGRAM: LHD MODEL B301 ABSCM&H/U B303 SHIELD JOINT CONNECTOR FRONT FRONT REAR REAR SENSOR LH SENSOR RH SENSOR LH SENSOR RH B301 B303 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 5 6 7...
  • Page 282 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) RHD MODEL ABSCM&H/U SHIELD JOINT CONNECTOR B200 FRONT FRONT REAR REAR SENSOR LH SENSOR RH SENSOR LH SENSOR RH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 1 2 3 4...
  • Page 283 Subaru Select Monitor. the steering wheel is in 2)Read the ABS wheel speed sensor output straight-ahead position? corresponding to faulty system in the Subaru Select Monitor data display mode. CHECK INSTALLATION OF ABS WHEEL Are the ABS wheel speed sen- Go to step 3.
  • Page 284 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK ABS WHEEL SPEED SENSOR. Is the resistance as following Go to step 9. Replace the ABS 1)Turn the ignition switch to OFF. value? wheel speed sen- 2)Disconnect the connector from ABS wheel Front: 1 —...
  • Page 285 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 13. Repair the har- Measure the voltage between ABSCM&H/U ness between connector and chassis ground. ABSCM&H/U and Connector &...
  • Page 286 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK ABS WHEEL SPEED SENSOR GAP. Is the gap as following value? Go to step 16. Adjust the gap. Measure the tone wheel to ABS wheel speed Front wheel: NOTE: sensor piece gap over entire perimeter of the 0.3 —...
  • Page 287 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK ABSCM&H/U. Is the same DTC as in current Replace the Go to step 21. 1)Connect all connectors. diagnosis still being output? ABSCM only. 2)Erase the memory. 3)Perform the inspection mode. 4)Read out the DTC.
  • Page 288 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) J: DTC 28 REAR LEFT ABNORMAL ABS WHEEL SPEED SENSOR SIGNAL DIAGNOSIS: • Faulty ABS wheel speed sensor signal (noise, irregular signal, etc.) • Faulty harness/connector TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL B301...
  • Page 289 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) RHD MODEL ABSCM&H/U SHIELD JOINT CONNECTOR B200 FRONT FRONT REAR REAR SENSOR LH SENSOR RH SENSOR LH SENSOR RH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 1 2 3 4...
  • Page 290 Subaru Select Monitor. the steering wheel is in 2)Read the ABS wheel speed sensor output straight-ahead position? corresponding to faulty system in the Subaru Select Monitor data display mode. CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 3.
  • Page 291 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK ABS WHEEL SPEED SENSOR SIG- Is an oscilloscope pattern Go to step 15. Go to step 12. NAL. smooth, as shown in the fig- 1)Raise all four wheels off ground. ure? 2)Turn the ignition switch to OFF.
  • Page 292 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK RESISTANCE OF ABS WHEEL Is the resistance as following Go to step 16. Replace the ABS SPEED SENSOR. value? wheel speed sen- 1)Turn the ignition switch to OFF. Front: 1 —...
  • Page 293 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 Go to step 20. Repair the Ω? Measure the resistance between ABSCM&H/U ABSCM&H/U and chassis ground. ground harness. Connector &...
  • Page 294 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) K: DTC 29 ABNORMAL ABS WHEEL SPEED SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR DIAGNOSIS: • Faulty ABS wheel speed sensor signal (noise, irregular signal, etc.) • Faulty tone wheel •...
  • Page 295 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) WIRING DIAGRAM: LHD MODEL B301 ABSCM&H/U B303 SHIELD JOINT CONNECTOR FRONT FRONT REAR REAR SENSOR LH SENSOR RH SENSOR LH SENSOR RH B301 B303 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 5 6 7...
  • Page 296 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) RHD MODEL ABSCM&H/U SHIELD JOINT CONNECTOR B200 FRONT FRONT REAR REAR SENSOR LH SENSOR RH SENSOR LH SENSOR RH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 1 2 3 4...
  • Page 297 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK IF THE WHEELS HAVE TURNED Is the wheels have been turned The ABS is nor- Go to step 2. FREELY FOR A LONG TIME. freely for more than one mal.
  • Page 298 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK CONTAMINATION OF ABS WHEEL Is the ABS wheel speed sen- Thoroughly Go to step 10. SPEED SENSOR OR TONE WHEEL. sor piece or tone wheel con- remove dirt or Remove the disc rotor or drum from hub.
  • Page 299 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) O: DTC 37 REAR LEFT INLET VALVE MALFUNCTION DIAGNOSIS: • Faulty harness/connector • Faulty inlet solenoid valve TROUBLE SYMPTOM: • ABS does not operate. • EBD does not operate. NOTE: In addition to the ABS warning light, brake warning light illuminates. ABS(diag)-63...
  • Page 300 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) WIRING DIAGRAM: BATTERY GENERATOR IGNITION SWITCH B108 *1: LHD 5 RELAY HOLDER RHD 3 *2: LHD 6 B225 RHD 4 B301 *3: LHD RELAY B264 B200 ABSCM&H/U B264 B225 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...
  • Page 301 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 — 15 V? Go to step 2. Repair the har- 1)Turn the ignition switch to OFF. ness connector 2)Disconnect the connector from ABSCM& between battery, H/U.
  • Page 302 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) S: DTC 38 REAR LEFT OUTLET VALVE MALFUNCTION DIAGNOSIS: • Faulty harness/connector • Faulty outlet solenoid valve TROUBLE SYMPTOM: • ABS does not operate. • EBD does not operate. NOTE: In addition to the ABS warning light, brake warning light illuminates. ABS(diag)-66...
  • Page 303 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) WIRING DIAGRAM: BATTERY GENERATOR IGNITION SWITCH B108 *1: LHD 5 RELAY HOLDER RHD 3 *2: LHD 6 B225 RHD 4 B301 *3: LHD RELAY B264 B200 ABSCM&H/U B264 B225 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...
  • Page 304 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 — 15 V? Go to step 2. Repair the har- 1)Turn the ignition switch to OFF. ness connector 2)Disconnect the connector from ABSCM& between battery, H/U.
  • Page 305 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) T: DTC 41 ABS CONTROL MODULE MALFUNCTION DIAGNOSIS: • Faulty ABSCM&H/U TROUBLE SYMPTOM: • ABS does not operate. • EBD does not operate. NOTE: In addition to the ABS warning light, brake warning light illuminates. WIRING DIAGRAM: B301 ABSCM&H/U...
  • Page 306 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 Go to step 2. Repair the Ω? 1)Turn the ignition switch to OFF. ABSCM&H/U 2)Disconnect the connector from ABSCM& ground harness.
  • Page 307 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) U: DTC 42 POWER SUPPLY VOLTAGE TOO LOW DIAGNOSIS: • Power source voltage of the ABSCM&H/U is low. TROUBLE SYMPTOM: • ABS does not operate. • EBD may not operate. NOTE: In addition to the ABS warning light, brake warning light illuminates temporarily when the EBD does not op- erate.
  • Page 308 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) WIRING DIAGRAM: BATTERY GENERATOR IGNITION SWITCH B108 *1: LHD 5 RELAY HOLDER RHD 3 *2: LHD 6 B225 RHD 4 B301 *3: LHD RELAY B264 B200 ABSCM&H/U B264 B225 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...
  • Page 309 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK GENERATOR. Is the voltage 10 — 17 V? Go to step 2. Repair the genera- 1)Start the engine. tor. <Ref. to 2)Idle after warm-up. SC(H4SO)-13, 3)Measure the voltage between generator B Generator.>...
  • Page 310 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) V: DTC 42 POWER SUPPLY VOLTAGE TOO HIGH DIAGNOSIS: • Power source voltage of the ABSCM&H/U is high. TROUBLE SYMPTOM: • ABS does not operate. • EBD may not operate. NOTE: In addition to the ABS warning light, brake warning light illuminates temporarily when the EBD does not op- erate.
  • Page 311 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) WIRING DIAGRAM: BATTERY GENERATOR IGNITION SWITCH B108 *1: LHD 5 RELAY HOLDER RHD 3 *2: LHD 6 B225 RHD 4 B301 *3: LHD RELAY B264 B200 ABSCM&H/U B264 B225 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...
  • Page 312 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK GENERATOR. Is the voltage 10 — 17 V? Go to step 2. Repair the genera- 1)Start the engine. tor. <Ref. to 2)Idle after warm-up. SC(H4SO)-13, 3)Measure the voltage between generator B Generator.>...
  • Page 313 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) W: DTC 44 ABS-AT CONTROL (NON CONTROLLED) DIAGNOSIS: • Combination of AT control faults TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: ABSCM&H/U B301 *1: LHD B200 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 10 11 12...
  • Page 314 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK GROUND SHORT OF HARNESS. Is the resistance more than 1 Go to step 3. Repair the har- 1)Turn the ignition switch to OFF. MΩ? ness between 2)Disconnect the two connectors from TCM. TCM and 3)Disconnect the connector from ABSCM&...
  • Page 315 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) X: DTC 44 ABS-AT CONTROL (CONTROLLED) DIAGNOSIS: • Combination of AT control faults TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: ABSCM&H/U B301 *1: LHD B200 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 10 11 12...
  • Page 316 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 2. Repair the har- 1)Turn the ignition switch to OFF. ness between 2)Disconnect all connectors from TCM. TCM and 3)Disconnect the connector from ABSCM&...
  • Page 317 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Y: DTC 51 VALVE RELAY MALFUNCTION DIAGNOSIS: • Faulty valve relay TROUBLE SYMPTOM: • ABS does not operate. • EBD may not operate. NOTE: In addition to the ABS warning light, brake warning light illuminates when the EBD does not operate. WIRING DIAGRAM: BATTERY SBF-3...
  • Page 318 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 — 15 V? Go to step 2. Repair the har- 1)Turn the ignition switch to OFF. ness connector 2)Disconnect the connector from ABSCM& between battery H/U.
  • Page 319 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Z: DTC 51 VALVE RELAY ON FAILURE DIAGNOSIS: • Faulty valve relay TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: BATTERY SBF-3 SBF-1 IGNITION SWITCH B108 RELAY HOLDER *1: LHD 5 RHD 3 *2: LHD 6 RHD 4...
  • Page 320 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK VALVE RELAY IN ABSCM&H/U. Is the resistance more than 1 Go to step 2. Replace the 1)Disconnect the connector from ABSCM& MΩ? ABSCM&H/U. H/U. <Ref. to ABS-6, 2)Measure the resistance between ABS Control Mod- ABSCM&H/U terminals.
  • Page 321 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) AA:DTC 52 OPEN CIRCUIT IN MOTOR RELAY CIRCUIT DIAGNOSIS: • Faulty motor • Faulty motor relay • Faulty harness connector TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: BATTERY SBF-1 IGNITION SWITCH B108...
  • Page 322 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 — 15 V? Go to step 2. Repair the har- 1)Turn the ignition switch to OFF. ness/connector 2)Disconnect the connector from ABSCM& between battery H/U.
  • Page 323 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) AB:DTC 52 MOTOR RELAY ON FAILURE DIAGNOSIS: • Faulty motor • Faulty motor relay • Faulty harness connector TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: BATTERY SBF-1 IGNITION SWITCH B108 RELAY HOLDER...
  • Page 324 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK MOTOR RELAY IN ABSCM&H/U. Is the resistance more than 1 Go to step 2. Replace the 1)Disconnect the connector from ABSCM& MΩ? ABSCM&H/U. H/U. <Ref. to ABS-6, 2)Measure the resistance between ABS Control Mod- ABSCM&H/U terminals.
  • Page 325 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) AC:DTC 52 MOTOR MALFUNCTION DIAGNOSIS: • Faulty motor • Faulty motor relay • Faulty harness connector TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: BATTERY SBF-1 IGNITION SWITCH B108 RELAY HOLDER *1: LHD 5 RHD 3...
  • Page 326 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 — 15 V? Go to step 2. Repair the har- 1)Turn the ignition switch to OFF. ness/connector 2)Disconnect the connector from ABSCM& between battery H/U.
  • Page 327 Go to step 3. USING SUBARU SELECT MONITOR. monitor display less than 1.5 1)Select “Current data display & Save” on the Subaru Select Monitor. 2)Release the brake pedal. 3)Read the stop light switch output in Subaru Select Monitor data display. ABS(diag)-91...
  • Page 328 Go to step 3. USING SUBARU SELECT MONITOR. monitor display 10 — 15 V? 1)Depress the brake pedal. 2)Read the stop light switch output in Subaru Select Monitor data display. CHECK IF STOP LIGHTS COME ON. Do the stop lights turn on? Go to step 4.
  • Page 329 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) AE:DTC 56 OPEN OR SHORT CIRCUIT IN G SENSOR CIRCUIT DIAGNOSIS: • Faulty G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABSCM&H/U B301 SHIELD JOINT CONNECTOR B303 JOINT CONNECTOR...
  • Page 330 SUBARU SELECT MONITOR. itor display 2.1 — 2.5 V when 1)Select “Current data display & Save” on the G sensor is in horizontal posi- Subaru Select Monitor. tion? 2)Read the G sensor output in Subaru Select Monitor data display. ABS(diag)-94...
  • Page 331 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 3. nector between ABSCM&H/U nector. and G sensor? CHECK ABSCM&H/U. Is the same DTC as in the cur- Replace the Go to step 4.
  • Page 332 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 12. Turn the ignition switch to OFF. nector between ABSCM&H/U nector. and G sensor? CHECK ABSCM&H/U.
  • Page 333 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) AF:DTC 56 BATTERY SHORT IN G SENSOR CIRCUIT DIAGNOSIS: • Faulty G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABSCM&H/U B301 SHIELD JOINT CONNECTOR B303 JOINT CONNECTOR (LATERAL G SENSOR)
  • Page 334 Go to step 2. Go to step 5. SUBARU SELECT MONITOR. when G sensor is in horizontal 1)Select “Current data display & Save” on the position? Subaru Select Monitor. 2)Read the G sensor output in Subaru Select Monitor data display. ABS(diag)-98...
  • Page 335 1)Select “Freeze frame data” on the Subaru on monitor display 0 km/h (0 Select Monitor. MPH)? 2)Read front right wheel speed on the Subaru Select Monitor display. CHECK FREEZE FRAME DATA. Is the front left wheel speed on Go to step 7.
  • Page 336 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 13. Repair the har- 1)Turn the ignition switch to ON. ness between G 2)Measure the voltage between ABSCM&H/U sensor and connector and chassis ground.
  • Page 337 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK G SENSOR. Is the voltage 0.5 — 0.9 V Go to step 21. Replace the G Measure the voltage between G sensor con- when G sensor is inclined sensor.
  • Page 338 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) AG:DTC 56 ABNORMAL G SENSOR HIGH µ µ µ µ OUTPUT DIAGNOSIS: • Faulty G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABSCM&H/U B301 SHIELD JOINT CONNECTOR B303...
  • Page 339 Go to step 2. Go to step 6. SUBARU SELECT MONITOR. when G sensor is in horizontal 1)Select “Current data display & Save” on the position? Subaru Select Monitor. 2)Read G sensor output on the Subaru Select Monitor display. ABS(diag)-103...
  • Page 340 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 3. Turn the ignition switch to OFF. nector between ABSCM&H/U nector. and G sensor? CHECK ABSCM&H/U.
  • Page 341 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK ABSCM&H/U. Is the same DTC as in current Replace the Go to step 11. 1)Turn the ignition switch to OFF. diagnosis still being output? ABSCM only. 2)Connect all connectors. <Ref.
  • Page 342 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) AH:DTC 56 DETECTION OF G SENSOR STICK DIAGNOSIS: • Faulty G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABSCM&H/U B301 SHIELD JOINT CONNECTOR B303 JOINT CONNECTOR (LATERAL G SENSOR) B261...
  • Page 343 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) RHD MODEL ABSCM&H/U SHIELD JOINT CONNECTOR B200 JOINT CONNECTOR (LATERAL G SENSOR) B261 B292 B257 G SENSOR LATERAL G SENSOR (STi MODEL) B257 B261 B292 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 1 2 3 4 5 6...
  • Page 344 1)Select “Current data display & Save” on the the vehicle is in horizontal posi- Subaru Select Monitor. tion? 2)Read the Subaru Select Monitor display. CHECK OUTPUT OF G SENSOR USING Is the voltage 3.7 — 4.1 V Go to step 4.
  • Page 345 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK G SENSOR. Is the voltage 0.5 — 0.9 V Go to step 12. Replace the G Measure the voltage between G sensor con- when G sensor is inclined sensor.
  • Page 346 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) AI: DTC 73 OPEN OR SHORT CIRCUIT IN LATERAL G SENSOR CIRCUIT DIAGNOSIS: • Faulty Lateral G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABSCM&H/U B301 SHIELD JOINT...
  • Page 347 2.3 — 2.7 V 1)Select “Current data display & Save” on the when lateral G sensor is in hor- Subaru Select Monitor. izontal position? 2)Read the lateral G sensor output in Subaru Select Monitor data display. ABS(diag)-111...
  • Page 348 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 3. nector between ABSCM&H/U nector. and lateral G sensor? CHECK ABSCM&H/U. Is the same DTC as in the cur- Replace the Go to step 4.
  • Page 349 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK LATERAL G SENSOR. Is the voltage 0.5 — 0.9 V Go to step 11. Replace the lateral Measure the voltage between lateral G sensor when lateral G sensor is G sensor.
  • Page 350 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) AJ:DTC 73 BATTERY SHORT IN LATERAL G SENSOR CIRCUIT DIAGNOSIS: • Faulty Lateral G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABSCM&H/U B301 SHIELD JOINT CONNECTOR B303 JOINT CONNECTOR...
  • Page 351 Go to step 5. USING SUBARU SELECT MONITOR. when lateral G sensor is in hor- 1)Select “Current data display & Save” on the izontal position? Subaru Select Monitor. 2)Read the lateral G sensor output in Subaru Select Monitor data display. ABS(diag)-115...
  • Page 352 1)Select “Freeze frame data” on the Subaru on monitor display 0 km/h (0 Select Monitor. MPH)? 2)Read front right wheel speed on the Subaru Select Monitor display. CHECK FREEZE FRAME DATA. Is the front left wheel speed on Go to step 7.
  • Page 353 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 13. Repair the har- 1)Turn the ignition switch to ON. ness between lat- 2)Measure the voltage between ABSCM&H/U eral G sensor and connector and chassis ground.
  • Page 354 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK LATERAL G SENSOR. Is the voltage 0.5 — 0.9 V Go to step 21. Replace the lateral Measure the voltage between lateral G sensor when lateral G sensor is G sensor.
  • Page 355 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) AK:DTC 73 ABNORMAL LATERAL G SENSOR HIGH µ µ µ µ OUTPUT DIAGNOSIS: • Faulty Lateral G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABSCM&H/U B301 SHIELD JOINT...
  • Page 356 Go to step 2. Go to step 6. USING SUBARU SELECT MONITOR. when Lateral G sensor is in 1)Select “Current data display & Save” on the horizontal position? Subaru Select Monitor. 2)Read Lateral G sensor output on the Subaru Select Monitor display. ABS(diag)-120...
  • Page 357 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 3. Turn the ignition switch to OFF. nector between ABSCM&H/U nector. and lateral G sensor? CHECK ABSCM&H/U.
  • Page 358 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK ABSCM&H/U. Is the same DTC as in current Replace the Go to step 11. 1)Turn the ignition switch to OFF. diagnosis still being output? ABSCM only. 2)Connect all connectors. <Ref.
  • Page 359 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) AL:DTC 73 DETECTION OF LATERAL G SENSOR STICK DIAGNOSIS: • Faulty Lateral G sensor output voltage TROUBLE SYMPTOM: • ABS does not operate. WIRING DIAGRAM: LHD MODEL ABSCM&H/U B301 SHIELD JOINT CONNECTOR B303 JOINT CONNECTOR...
  • Page 360 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) RHD MODEL ABSCM&H/U SHIELD JOINT CONNECTOR B200 JOINT CONNECTOR (LATERAL G SENSOR) B261 B292 B257 G SENSOR LATERAL G SENSOR (STi MODEL) B257 B261 B292 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 1 2 3 4 5 6...
  • Page 361 1)Select “Current data display & Save” on the when the vehicle is in horizon- Subaru Select Monitor. tal position? 2)Read the Subaru Select Monitor display. CHECK OUTPUT OF LATERAL G SENSOR Is the voltage 3.7 — 4.1 V Go to step 4.
  • Page 362 Diagnostics Procedure with Diagnostic Trouble Code (DTC) ABS (DIAGNOSTICS) Step Check CHECK LATERAL G SENSOR. Is the voltage 0.5 — 0.9 V Go to step 12. Replace the lateral Measure the voltage between lateral G sensor when lateral G sensor is G sensor.
  • Page 363 General Diagnostics Table ABS (DIAGNOSTICS) 14.General Diagnostics Table A: INSPECTION Symptom Probable faulty units/parts • ABSCM&H/U (solenoid valve) • ABS wheel speed sensor • Brake (caliper & piston, pads) Vehicle pulls to either side. • Wheel alignment • Tire specifications, tire wear and air pressures •...
  • Page 364 General Diagnostics Table ABS (DIAGNOSTICS) ABS(diag)-128...
  • Page 365 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 366 BRAKE Page General Description ..................2 Front Brake Pad ..................25 Front Disc Rotor ..................29 Front Disc Brake Assembly...............31 Rear Brake Pad..................37 Rear Disc Rotor..................40 Rear Disc Brake Assembly ...............42 Rear Drum Brake Shoe................47 Rear Drum Brake Drum ................49 Rear Drum Brake Assembly..............50 Master Cylinder ..................53 Brake Booster ...................55 Proportioning Valve...................59...
  • Page 367 General Description BRAKE 1. General Description A: SPECIFICATIONS Model BASE, TS GX, RS, OBK Size 14 inch type 15 inch type 16 inch type 17 inch type Type Disc (Floating type, ventilated) Disc (Fixed type, ventilated) Effective disc 210 mm (8.27 in) 228 mm (8.98 in) 255 mm (10.04 in) 268 mm (10.55 in)
  • Page 368 General Description BRAKE Model BASE, TS GX, RS, OBK 1,961 kPa Propor- Split point — tioning (20 kg/cm , 285 psi) valve Reduce ratio — Brake line Dual circuit system Brake fluid CAUTION: • Avoid mixing brake fluid of different brands to pre- vent the fluid performance from degrading.
  • Page 369 General Description BRAKE Fluid pressure Brake pedal BASE, TS force GX, RS, OBK Without ABS With ABS 686 kPa 588 kPa 588 kPa 147 N (7 kg/cm (6 kg/cm (15 kgf, 33 lb) (6 kg/cm , 85 psi) 100 psi) 85 psi) Brake fluid pressure without engine running...

  • Page 370: Front Disc Brake

    General Description BRAKE B: COMPONENT 1. FRONT DISC BRAKE • 14 INCH TYPE (17) (16) (15) (11) (10) (12) (12) (11) (14) (13) BR-00377 Caliper body Support (17) Bushing Air bleeder screw (10) Pad clip Guide pin (Green) (11) Outer shim Tightening torque: N·m (kgf-m, ft-lb) Pin boot (12)
  • Page 371 General Description BRAKE • 15 INCH TYPE (17) (10) (16) (11) (12) (14) (13) (12) (11) (15) BR-00378 Caliper body Support (17) Bushing Air bleeder screw (10) Pad clip Guide pin (Green) (11) Outer shim Tightening torque: N·m (kgf-m, ft-lb) Pin boot (12) Inner shim...
  • Page 372 General Description BRAKE • 16 INCH TYPE (10) (11) (12) (14) (10) (13) (12) (17) (11) (15) (17) (16) BR-00379 Housing Piston boot (17) Spacer Air bleeder screw (10) Boot ring Caliper body (11) Outer shim Tightening torque: N·m (kgf-m, ft-lb) M clip (12) Inner shim...
  • Page 373 General Description BRAKE • 17 INCH TYPE (11) (10) (12) (14) (10) (13) (12) (11) (15) (16) BR-00380 Housing Piston boot (15) Disc rotor Caliper body Piston (16) Disc cover Air bleeder screw (10) Piston seal Guide plate (11) Pad shim (Outside) Tightening torque: N·m (kgf-m, ft-lb) Cross spring (12)

  • Page 374: Rear Disc Brake

    General Description BRAKE 2. REAR DISC BRAKE • 14 INCH TYPE ( 2) ( 3) ( 4) (1 ) (5 ) ( 10 ) ( 6) (7 ) (8 ) (1 4) (9 ) (12 ) (3 3) ( 4 ) (1 1) (1 4 ) (1 7)
  • Page 375 General Description BRAKE • 15 INCH TYPE (15) (14) (13) (10) (11) (12) (12) (18) (11) (16) (17) (19) (20) (21) (24) (33) (22) (25) (26) (27) (28) (23) (30) (29) (32) (31) BR-00327 Caliper body (14) Washer (27) Secondary shoe return spring Air bleeder screw (15) Cross spring...
  • Page 376 General Description BRAKE • 17 INCH TYPE (10) (12) (11) (10) (15) (13) (14) (16) (17) (18) (19) (30) (21) (22) (23) (24) (25) (20) (26) (27) (29) (28) BR-00281 Caliper body (13) Shoe hold-down pin (25) Primary shoe return spring Air bleeder screw (14) Cover...
  • Page 377 General Description BRAKE 3. REAR DRUM BRAKE (12) (13) (14) (17) (15) (24) (18) (10) (19) (11) (22) (16) (20) (21) (23) BR-00004 Air bleeder cap (11) Upper shoe return spring (21) Lower shoe return spring Air bleeder screw (12) Retainer (22) Adjusting spring...
  • Page 378 General Description BRAKE 4. MASTER CYLINDER • LHD MODEL (10) BR-00153 Secondary piston Tightening torque: N·m (kgf-m, ft-lb) Filter Cylinder body T1: 15 (1.5, 10.8) Reservoir tank Cylinder pin Piston retainer Seal Primary piston (10) BR-13...
  • Page 379 General Description BRAKE • RHD MODEL (10) BR-00196 Secondary piston Tightening torque: N·m (kgf-m, ft-lb) Filter Cylinder body T1: 15 (1.5, 10.8) Reservoir tank Cylinder pin Piston retainer Seal Primary piston (10) BR-14...
  • Page 380 General Description BRAKE 5. FRONT BRAKE PIPES AND HOSE • LHD MODEL (11) (11) (10) BR-00283 Model without ABS Model with ABS Model with ABS (with hill holder) Front brake pipe assembly ABS control module and hydraulic Tightening torque: N·m (kgf-m, ft-lb) control unit (ABSCM&H/U) Proportioning valve T1: 15 (1.5, 10.8)
  • Page 381 General Description BRAKE • RHD MODEL (11) (3) (5) (11) (11) (10) BR-00284 Model without ABS Model with ABS Model with ABS (With hill holder) Front brake pipe assembly ABS control module and hydraulic Tightening torque: N·m (kgf-m, ft-lb) control unit (ABSCM&H/U) Proportioning valve T1: 15 (1.5, 10.8) Front brake hose RH...
  • Page 382 General Description BRAKE 6. CENTER AND REAR BRAKE PIPES AND HOSES BR-00007 Center brake pipe assembly Rear brake hose LH (Disc brake Tightening torque: N·m (kgf-m, ft-lb) model) Two-way connector T1: 15 (1.5, 10.8) Rear brake pipe assembly Rear brake hose LH (Drum brake T2: 18 (1.8, 13.0) model) Rear brake hose RH (Disc brake...
  • Page 383 General Description BRAKE 7. BRAKE BOOSTER • MODEL With ABS (11) (10) ( 8 ) (12) ( 7 ) ( 1 ) ( 2 ) ( 4 ) ( 5 ) ( 6 ) ( 3 ) ( 9 ) BR-00008 Push rod Filter...
  • Page 384 General Description BRAKE 8. BRAKE PEDAL • 1.6 L MODEL (17) (16) (11) (12) (15) (18) (15) (14) (13) (13) (14) (10) BR-00286 Stopper (10) Clutch pedal Tightening torque: N·m (kgf-m, ft-lb) Bushing (11) Clutch cable T1: 5.9 (0.6, 4.3) Pedal bracket (12) Clutch cable clamp...
  • Page 385 General Description BRAKE • 2.0 L AND 2.5 L MODEL (26) (11) (25) (24) (23) (11) (28) (22) (20) (21) (19) (18) (14) (14) (13) (27) (17) (16) (15) (12) (11) (23) (29) (10) BR-00287 Stopper (13) Assist rod A (25) Clutch master cylinder bracket Bushing...
  • Page 386 General Description BRAKE • LHD AT MODEL BR-00139 Stopper Brake pedal pad Tightening torque: N·m (kgf-m, ft-lb) Bushing Brake pedal T1: 8 (0.8, 5.8) Pedal bracket Clevis pin T2: 18 (1.8, 13.0) Stop light switch Brake pedal spring T3: 29 (3.0, 21.7) Snap pin BR-21...
  • Page 387 General Description BRAKE • RHD MODEL BR-00010 Stopper Brake pedal pad Tightening torque: N·m (kgf-m, ft-lb) Snap pin Brake pedal bracket ASSY T1: 8 (0.8, 5.8) Clevis pin Cover T2: 18 (1.8, 13.0) Stop light switch Protector T3: 33 (3.3, 24.3) Brake pedal BR-22...
  • Page 388 • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary re- moval, installation, disassembly, and replacement. • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease etc. with that of another grade or from other manufacturers.
  • Page 389 General Description BRAKE D: PREPARATION TOOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925460000 WHEEL CYLINDER Used for installing cup onto wheel cylinder piston 11/16″ ADAPTER (Size 11/16″). ST-925460000 2. GENERAL PURPOSE TOOLS TOOL NAME REMARKS SNAP RING PLIERS Used for removing and installing snap ring.

  • Page 390: Front Brake Pad

    Front Brake Pad BRAKE 2. Front Brake Pad (4) Attach a rod of less than 12 mm (0.47 in) dia. to the shaded area of brake pad, and strike the A: REMOVAL rod with a hammer to drive brake pad out of place.
  • Page 391 Front Brake Pad BRAKE 6) Use a wrench to expand the pads, and then 5) Remove the pad pins and cross spring. push the piston back. BR-00293 BR-00290 (1) Pad pin 7) Remove the pad. (2) Cross spring 6) Use a wrench to expand the pads, and then push the piston back.
  • Page 392 Front Brake Pad BRAKE B: INSTALLATION 3. 17 INCH TYPE 1) Apply thin coat of Molykote AS880N (Part No. 1. 14 INCH AND 15 INCH TYPE K0779YA010) to the frictional portion between pad 1) Apply thin coat of Molykote AS880N (Part No. and pad shim.
  • Page 393 Front Brake Pad BRAKE 2. 16 INCH TYPE • Replace the pad if there is oil or grease on it. Check the pad thickness A. BR-00296 Standard value 10 mm (0.393 in) Pad thickness Wear limit 1.5 mm (0.59 in) NOTE: •...
  • Page 394 Front Disc Rotor BRAKE 3. Front Disc Rotor 4) Remove the caliper body from housing and sus- pend from strut using a wire. A: REMOVAL 1. 14 INCH AND 15 INCH TYPE 1) Set the vehicle on a lift. 2) Loosen the wheel nuts. 3) Lift-up the vehicle, and then remove the front wheel.
  • Page 395 Front Disc Rotor BRAKE If the disc rotor runout is above specified value, re- place the disc rotor. BR-00019 Disc rotor runout limit: 0.075 mm (0.0030 in) 4) Set a micrometer 10 mm (0.39 in) inward of the rotor outer perimeter, and then measure the disc rotor thickness.
  • Page 396 Front Disc Brake Assembly BRAKE 4. Front Disc Brake Assembly NOTE: Remove the support only when replacing it or the A: REMOVAL rotor. It need not be removed when servicing the caliper body assembly. 1. 14 INCH AND 15 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body;...
  • Page 397 Front Disc Brake Assembly BRAKE 4) Remove the brake pads from caliper body. <Ref. 7) Bleed air from the brake system. to BR-26, 17 INCH TYPE, REMOVAL, Front Brake 2. 16 INCH TYPE Pad.>. 5) Remove the union bolt and brake hose from cal- 1) Install the caliper body on housing.
  • Page 398 Front Disc Brake Assembly BRAKE 7) Replace the brake hose gaskets with new ones, 2. 16 INCH TYPE and then connect the brake hose. 1) Clean mud and foreign particles from the caliper Tightening torque: body assembly. 18 N·m (1.8 kgf-m, 13.0 ft-lb) CAUTION: 8) Bleed air from the brake system.
  • Page 399 Front Disc Brake Assembly BRAKE 5) Remove the piston seal from caliper body cylin- CAUTION: der. Do not damage the cylinder and piston seal groove. CAUTION: Do not damage the cylinder and piston seal groove. BR-00305 (1) Piston seal BR-00305 3.
  • Page 400 Front Disc Brake Assembly BRAKE 6) Position the boot in grooves on cylinder and pis- CAUTION: ton. Do not force the piston into cylinder. BR-00122 BR-00307 6) Position the boot in grooves on cylinder and pis- (1) Piston ton. (2) Piston boot (3) Caliper body (4) Piston seal 7) Apply a coat of specified grease to the lock pin...
  • Page 401 Front Disc Brake Assembly BRAKE CAUTION: Do not force the piston into cylinder. BR-00307 6) Position the boot in grooves on cylinder and pis- ton. BR-00309 (1) Piston seal (2) Piston boot (3) Piston E: INSPECTION 1) Repair or replace the faulty parts. 2) Check the caliper body and piston for uneven wear, damage or rust.
  • Page 402 Rear Brake Pad BRAKE 5. Rear Brake Pad 4) Remove the M clip. A: REMOVAL 1. 14 INCH TYPE 1) Set the vehicle on a lift. 2) Loosen the wheel nuts. 3) Lift-up the vehicle, and then remove the rear wheel.
  • Page 403 Rear Brake Pad BRAKE 4) Remove the clip. NOTE: If it is difficult to push the piston during pad replace- ment, loosen air bleeder to facilitate work. 2. 15 INCH TYPE 1) Apply a thin coat of Molykote AS880N (Part No. K0777YA010) to frictional portion between pad and pad inner shim.
  • Page 404 Rear Brake Pad BRAKE 2. 15 INCH TYPE • Replace the pad if there is oil or grease on it. Check the pad thickness A. BR-00314 Standard value 11.5 mm (0.452 in) Pad thickness Wear limit 1.5 mm (0.059 in) NOTE: •...

  • Page 405: Rear Disc Rotor

    Rear Disc Rotor BRAKE 6. Rear Disc Rotor (2) If the disc rotor seizes up within hub, drive the disc rotor out by installing an 8-mm bolt in A: REMOVAL holes B on rotor. 1) Set the vehicle on a lift. 2) Loosen the wheel nuts.
  • Page 406 Rear Disc Rotor BRAKE 4) Set a micrometer 10 mm (0.39 in) inward of the rotor outer perimeter, and then measure the disc rotor thickness. If the thickness of disc rotor is out- side the service limit, replace the disc rotor. BR-00036 Standard Service...
  • Page 407 Rear Disc Brake Assembly BRAKE 7. Rear Disc Brake Assembly 6) Remove the caliper body from housing. A: REMOVAL 1. 14 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled.
  • Page 408 Rear Disc Brake Assembly BRAKE B: INSTALLATION C: DISASSEMBLY 1. 14 INCH TYPE 1. 14 INCH TYPE 1) Install the support on housing. 1) Remove the boot ring. Tightening torque: 52 N·m (5.3 kgf-m, 38.3 ft-lb) 2) Apply thin coat of Molykote AS880N (Part No. K0777YA010) to the frictional portion between pad and pad clip.
  • Page 409 Rear Disc Brake Assembly BRAKE 4) Gradually supply compressed air via the installa- CAUTION: tion hole of brake hose to force the piston out. Do not damage the cylinder and piston seal groove. BR-00318 BR-00043 (1) Place a 30 mm (1.18 in) wide wooden block 6) Remove the lock pin sleeve and boot from cali- here.
  • Page 410 Rear Disc Brake Assembly BRAKE 3) Gradually supply compressed air via the installa- 6) Install the piston boot to caliper body, and then tion hole of brake hose to force the piston out. attach boot ring. BR-00318 BR-00029 (1) Place a 20 mm (0.79 in) wide wooden block (1) Piston boot here.
  • Page 411 Rear Disc Brake Assembly BRAKE E: INSPECTION CAUTION: Do not force piston into cylinder. 1) Repair or replace the faulty parts. 2) Check the caliper body and piston for uneven 6) Install the piston boot to the caliper body, and wear, damage or rust.
  • Page 412 Rear Drum Brake Shoe BRAKE 8. Rear Drum Brake Shoe 6) Hold the hold-down pin by securing rear of back plate with your hand. A: REMOVAL 1) Set the vehicle on a lift. 2) Loosen the wheel nuts. 3) Lift-up the vehicle, and then remove the wheels. 4) Release the parking brake.
  • Page 413 Rear Drum Brake Shoe BRAKE 10) Disconnect the parking brake cable from park- Brake grease: ing lever. Dow Corning Molykote No. 7439 (Part No. 003602001) BR-00051 BR-00054 (1) Parking brake cable 4) Connect the upper shoe return spring to shoes. (2) Trailing shoe 5) Connect the parking brake cable to parking le- (3) Parking brake lever...

  • Page 414: Rear Drum Brake Drum

    Rear Drum Brake Drum BRAKE 9. Rear Drum Brake Drum 2) Measure the drum inner diameter. If the inner di- ameter of drum is outside the service limit, replace A: REMOVAL the drum. 1) Set the vehicle on a lift. Drum inner diameter: “L”...
  • Page 415 Rear Drum Brake Assembly BRAKE 10.Rear Drum Brake Assembly Tightening torque: 10 N·m (1.0 kgf-m, 7.2 ft-lb) A: REMOVAL CAUTION: Do not allow brake fluid to come in contact with vehicle body; wash away with water and wipe off completely if spilled. 1) Set the vehicle on a lift.
  • Page 416 Rear Drum Brake Assembly BRAKE Tightening torque: D: ASSEMBLY 32 N·m (3.3 kgf-m, 24 ft-lb) 1) Clean all parts in brake fluid. Check and replace 8) Apply grease to the adjusting screw and both the faulty parts. ends of adjuster. •...
  • Page 417 Rear Drum Brake Assembly BRAKE Grease: NIGLUBE RX-2 (Part No. K0779GA102) BR-00068 E: INSPECTION If the deformation or wear of back plate, shoe, etc. are notable, replace them. BR-52...
  • Page 418 Master Cylinder BRAKE 11.Master Cylinder 5) Pry up the pawl, and then remove the piston re- tainer. Hold piston retainer tight, because the pis- A: REMOVAL ton may jump out from master cylinder. CAUTION: Do not allow brake fluid to come in contact with vehicle body;...
  • Page 419 Master Cylinder BRAKE 12) Install the seal to reservoir tank. BR-00072 (1) Seal 13) Install the reservoir tank to master cylinder and secure with pin. D: INSPECTION Inspect for oil leakage from the master cylinder. NOTE: After replacing piston kit; when the oil leakage is found without damaging or scratching the inside of cylinder wear of master cylinder inner wall may be the cause.
  • Page 420 Brake Booster BRAKE 12.Brake Booster • Use care when placing the brake booster on floor. A: REMOVAL • Do not change the push rod length. If it has been 1) Remove or disconnect the following parts at en- changed, reset the projected length “L” to standard gine compartment.
  • Page 421 Brake Booster BRAKE 2) Mount the brake booster in position. CAUTION: 3) Connect the operating rod to brake pedal with Be careful not to rotate the stop light switch. clevis pin and snap pin. Stop light switch clearance: A 0.3 mm (0.012 in) BR-00079 9) Apply grease to operating rod connecting pin to prevent it from wearing.
  • Page 422 Brake Booster BRAKE • Air tightness check 3) As the engine starts, the brake pedal should move slightly toward the floor. If no change occurs Start the engine, and run it for 1 to 2 minutes, then in the pedal height, the brake booster is faulty. turn it off.
  • Page 423 Brake Booster BRAKE • Air tightness check 2) Stop the engine and watch vacuum gauge. If the vacuum drop range is less than 3.3 kPa (25 1) Start the engine and keep it running until a vac- mmHg, 0.98 inHg) within 15 seconds after stopping uum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A engine, the brake booster is functioning properly.
  • Page 424 Proportioning Valve BRAKE 13.Proportioning Valve The standard values are shown in the figure. A: REMOVAL BR-00086 BR-00085 (1) Rear wheel cylinder fluid pressure: P (2) Master cylinder fluid pressure: P 1) Remove the brake pipe from proportioning valve at four places. (3) When both circuits are normal 2) Remove the proportioning valve from its bracket.
  • Page 425 Brake Fluid BRAKE 14.Brake Fluid 5) Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container A: INSPECTION to collect the brake fluid. 1) Check that the brake fluid level remains between “MIN”...
  • Page 426 Brake Fluid BRAKE 8) Release the brake pedal slowly. Repeat steps 6) through 8) until there are no air bubbles in the drained brake fluid and new fluid flows through vi- nyl tube. NOTE: • Add brake fluid as necessary while performing air bleed operation, in order to prevent the tank from running short of brake fluid.
  • Page 427 Air Bleeding BRAKE 15.Air Bleeding 5) Close the outlet plug with your finger, and then release the brake pedal. A: PROCEDURE CAUTION: • The FMVSS No. 116, fresh DOT3 brake fluid must be used. • Cover the bleeder with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts.
  • Page 428 Air Bleeding BRAKE Air bleeder tightening torque: CAUTION: Except for 17 inch type: Brake fluid replacement sequence; (A) Front right → → → → (B) Rear left → → → → (C) Front left → → → → (D) Rear 8 N·m (0.8 kgf-m, 5.8 ft-lb) 17 inch type: right...
  • Page 429 Air Bleeding BRAKE 12) As a final step, test run the vehicle at low speed and apply brakes relatively hard 2 to 3 times to en- sure that brakes provide normal braking action on all four wheels without dragging and uneven brak- ing.
  • Page 430 Brake Hose BRAKE 16.Brake Hose 3) Separate the brake hose from wheel cylinder. A: REMOVAL 1. FRONT BRAKE HOSE 1) Separate the brake pipe from brake hose. (Always use the flare nut wrench and be careful not to deform the flare nut.) 2) Pull out the clamp to remove brake hose.
  • Page 431 Brake Hose BRAKE 2. REAR BRAKE HOSE (DISC BRAKE) Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) 1) Pass the brake hose through hole of bracket, and then lightly tighten the flare nut to connect brake pipe. 2) Insert the clamp upward to fix brake hose. 3) Install the brake hose to caliper using a new gas- ket.
  • Page 432 Brake Pipe BRAKE 17.Brake Pipe A: REMOVAL NOTE: Airbag system wiring harness is routed near the center brake pipe. CAUTION: • All airbag system wiring harness and con- nectors are colored yellow. Do not use electri- cal test equipment on these circuits. •...
  • Page 433 Brake Pedal BRAKE 18.Brake Pedal 4) Remove the nut which secures the clutch master cylinder. A: REMOVAL 5) Remove the accelerator pedal. 6) Remove the bolts and nuts which the secure 1. LHD 1.6 L MT MODEL pedal bracket. 1) Disconnect the ground cable from battery. 2) Disconnect the clutch cable from release lever.
  • Page 434 Brake Pedal BRAKE 4) Remove the four bolts and four nuts which se- 5) Remove the four bolts which secure the brake cure the brake pedal to pedal. pedal bracket (rear side). BR-00140 BR-00135 6) Remove the nuts which secure the brake pedal (1) Clevis pin bracket (front side).
  • Page 435 Brake Pedal BRAKE 3) Inspect the brake pedal after installation <Ref. to 3) Remove the clutch master cylinder bracket. BR-71, INSPECTION, Brake Pedal.> C: DISASSEMBLY 1. LHD 1.6 L MT MODEL 1) Remove the stop light switch. <Ref. to BR-73, REMOVAL, Stop Light Switch.> 2) Remove the nut and pull out the bolt until brake pedal is able to remove, then remove brake pedal.
  • Page 436 Brake Pedal BRAKE 3) Remove the bushing, spacer and spring. 4) Adjust the stop light switch position after install- ing the brake pedal to vehicle. E: INSPECTION 1) Move the brake and clutch pedal pads in the lat- eral direction with a force of approx. 10 N (1 kgf, 2 lb) to ensure pedal deflection is in specified range.
  • Page 437 Brake Pedal BRAKE Brake pedal free play: A 1 — 3 mm (0.04 — 0.12 in) [Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb).] BR-00106 (1) Stop light switch (2) Mat (3) Toe board (4) Brake booster operating rod 3) If it is not within specified value, adjust it by ad- justing the brake booster operating rod length.
  • Page 438 Stop Light Switch BRAKE 19.Stop Light Switch Specified position: L 2 mm (0.079 in) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the stop light switch connector. 3) Loosen nuts, and unscrew stop light switch to re- move.
  • Page 439 Stop Light Switch BRAKE Tightening torque: 8 N·m (0.8 kgf-m, 5.8 ft-lb) BR-00111 (1) Stop light switch (2) Lock nut A (3) Lock nut B (4) Stopper (5) Brake pedal NOTE: Tighten the lock nut B until the clearance between threaded end of stop light switch and stopper be- comes 0 mm (0 in).
  • Page 440 Hill Holder BRAKE 20.Hill Holder CAUTION: Exercise utmost care to prevent foreign matter A: REMOVAL from entering into the PHV when removing it. 1. PHV (PRESSURE HOLD VALVE) 1) Drain the brake fluid from reservoir of master cyl- inder. 2) Remove the adjusting nut and lock nut. BR-00133 (1) PHV 2.
  • Page 441 Hill Holder BRAKE 3) Remove the cable clamp from clutch pedal C: INSTALLATION bracket. 1. PHV (PRESSURE HOLD VALVE) • LHD MODEL 1) Install the PHV onto side frame. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) 2) Connect the brake pipes to PHV. Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) CAUTION:...
  • Page 442 Hill Holder BRAKE D: ADJUSTMENT Confirm stopping and starting performances by ac- tivating the hill holder on an uphill road of 3° or high- er inclination. 1) If the vehicle does not stop; Tighten the adjusting nut of PHV cable. 2) If the vehicle does not start properly;...
  • Page 443 General Diagnostics BRAKE 21.General Diagnostics A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism Repair or replace (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose). (2) Entry of air into the hydraulic mechanism Bleed the air.
  • Page 444 General Diagnostics BRAKE Trouble and possible cause Corrective action 7. Brake noise (3) In the case of the disc brake: (click sound) (1) Excessively worn pad or the support Replace the pad or the support. In the case of the drum brake: (1) Excessively worn shoe ridge Replace the back plate.
  • Page 445 General Diagnostics BRAKE BR-80...
  • Page 446 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 447 PARKING BRAKE Page General Description ..................2 Parking Brake Lever..................4 Parking Brake Cable ...................5 Parking Brake Assembly (Rear Disc Brake) ..........6 General Diagnostic Table................9...
  • Page 448 General Description PARKING BRAKE 1. General Description A: SPECIFICATIONS Rear disc brake Model Rear drum brake Rear disc brake (STi model) Mechanical on rear Type Mechanical on rear brakes, drum in disc brakes Effective drum diameter mm (in) 228.6 (9) 170 (6.69) 190 (7.48) 218.8 ×...
  • Page 449 • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease etc. with that of another grade or from other manufacturers.
  • Page 450 Parking Brake Lever PARKING BRAKE 2. Parking Brake Lever If not as specified, adjust the parking brake. <Ref. to PB-8, ADJUSTMENT, Parking Brake Assembly A: REMOVAL (Rear Disc Brake).> 1) Set the wheel stopper to wheels. D: ADJUSTMENT 2) Remove the console box. Adjust the parking brake lever stroke.
  • Page 451 Parking Brake Cable PARKING BRAKE 3. Parking Brake Cable 10) Remove the parking brake cable from rear brake. A: REMOVAL Disc brake 1) Lift up the vehicle. <Ref. to PB-6, REMOVAL, Parking Brake Assem- 2) Remove the rear wheels. bly (Rear Disc Brake).> 3) Remove the rear seat cushion.
  • Page 452 Parking Brake Assembly (Rear Disc Brake) PARKING BRAKE 4. Parking Brake Assembly (2) If the disc rotor seizes up within hub, drive the disc rotor out by installing two 8-mm bolts in (Rear Disc Brake) holes B on rotor. A: REMOVAL 1) Pull down and release the parking brake.
  • Page 453 Parking Brake Assembly (Rear Disc Brake) PARKING BRAKE B: INSTALLATION • Install the adjuster assembly with screw on left side. CAUTION: Be sure the lining surface is free from oil and grease contamination. 1) Apply brake grease to the following places. Brake grease: Brake Grease (Part No.
  • Page 454 Parking Brake Assembly (Rear Disc Brake) PARKING BRAKE C: INSPECTION 6) Adjust the parking brake lever stroke. <Ref. to PB-8, LEVER STROKE, ADJUSTMENT, Parking 1) Measure the brake disc rotor inside diameter. If Brake Assembly (Rear Disc Brake).> the disc is scored or worn, replace the brake disc rotor.
  • Page 455 General Diagnostic Table PARKING BRAKE 5. General Diagnostic Table A: INSPECTION Symptom Possible cause Remedy Parking brake lever is maladjusted. Adjustment. Parking brake cable does not move. Repair or replace. Brake drag Parking brake shoe clearance is maladjusted. Adjustment. Return spring is faulty. Replace.
  • Page 456 General Diagnostic Table PARKING BRAKE PB-10...
  • Page 457 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 458 POWER ASSISTED SYSTEM (POWER STEERING) Page General Description ..................2 Steering Wheel..................23 Universal Joint...................24 Tilt Steering Column..................26 Steering Gearbox [LHD MODEL] ..............29 Steering Gearbox [RHD MODEL] .............47 Pipe Assembly [LHD MODEL] ..............64 Pipe Assembly [RHD MODEL]..............72 Oil Pump ....................80 Reservoir Tank..................85 Power Steering Fluid.................86 General Diagnostic Table................87...
  • Page 459 General Description POWER ASSISTED SYSTEM (POWER STEERING) 1. General Description A: SPECIFICATIONS 2.0 L Model 1.6 L DOHC TURBO 2.5 L Except OUT- OUTBACK BACK Minimum turning radius m (ft) 5.2 (17.1) 5.5 (18.0) Steering angle (Inside-Outside) 37.3° — 32.4° 34.5°...
  • Page 460 General Description POWER ASSISTED SYSTEM (POWER STEERING) Model Steering wheel Free play mm (in) 17 (0.67) TURBO, OUTBACK, RS 34.5°±1.5° Inner tire & wheel Except TURBO, OUTBACK, RS 37.3°±1.5° Turning angle TURBO, OUTBACK, RS 30.3°±1.5° Outer tire & wheel Except TURBO, OUTBACK, RS 32.4°±1.5°...
  • Page 461 General Description POWER ASSISTED SYSTEM (POWER STEERING) CAUTION: This table lists various clearances that must be correctly adjusted to ensure the normal vehicle driv- ing without interfering noise, or any other faults. Location Minimum allowance (1) Crossmember — Pipe 5 mm (0.20 in) (2) DOJ —...
  • Page 462 General Description POWER ASSISTED SYSTEM (POWER STEERING) • RHD MODEL PS-00428 PS-5...
  • Page 463 General Description POWER ASSISTED SYSTEM (POWER STEERING) B: COMPONENT 1. STEERING WHEEL AND COLUMN PS-00002 Bushing Steering wheel Tightening torque: N·m (kgf-m, ft-lb) Steering shaft Airbag module T1: 1.2 (0.12, 0.9) Steering roll connector Steering wheel lower cover T2: 25 (2.5, 18.1) Column cover T3: 45 (4.6, 33.2) PS-6...
  • Page 464 General Description POWER ASSISTED SYSTEM (POWER STEERING) 2. POWER ASSISTED SYSTEM • LHD MODEL (58) (58) (12) (57) (16) (10) (10) (57) (11) (16) (15) (11) (12) (13) (13) (14) (14) (19) (36) (37) (38) (58) (32) (35) (20) (18) (33) (34) (21)
  • Page 465 General Description POWER ASSISTED SYSTEM (POWER STEERING) NON-TURBO MODEL (24) Oil seal (50) Steering body TURBO MODEL (25) Ball bearing (51) Oil seal (26) Seal ring (52) Piston ring Eye bolt (27) Pinion and valve ASSY (53) Rack Pipe C (28) Oil seal (54)
  • Page 466 General Description POWER ASSISTED SYSTEM (POWER STEERING) • RHD MODEL (53) (53) (10) (16) (12) (52) (10) (52) (11) (11) (12) (16) (15) (13) (13) (14) (14) (28) (27) (31) (29) (17) (33) (30) (18) (34) (35) (19) (32) (20) (21) (25) (49)
  • Page 467 General Description POWER ASSISTED SYSTEM (POWER STEERING) NON-TURBO MODEL (23) Seal ring (48) Adjusting screw TURBO MODEL (24) Oil seal (49) Spring (25) Adapter (50) Sleeve Eye bolt (26) Clamp (51) Seat pad Pipe C (27) Castle nut (52) Suction hose Gasket (28) Cotter pin...
  • Page 468 General Description POWER ASSISTED SYSTEM (POWER STEERING) 3. OIL PUMP • EXCEPT DOHC TURBO MODEL PS-00024 (1) Oil pump ASSY PS-11...
  • Page 469 General Description POWER ASSISTED SYSTEM (POWER STEERING) • DOHC TURBO MODEL PS-00005 (1) Oil pump ASSY PS-12...
  • Page 470 • Be careful not to burn your hands, because each part on the vehicle is hot after running. • Use SUBARU genuine power steering fluid, grease etc. or the equivalent. Do not mix steering fluid, grease etc. with that of another grade or from other manufacturers.
  • Page 471 General Description POWER ASSISTED SYSTEM (POWER STEERING) D: PREPARATION TOOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925700000 WRENCH • Used for removing and installing tie-rod. • Apply this tool to rack. ST-925700000 925711000 PRESSURE Used for measuring oil pump pressure. GAUGE ST-925711000 926200000...
  • Page 472 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34099AC020 ADAPTER HOSE B Used with PRESSURE GAUGE (925711000). ST34099AC020 926230000 SPANNER For the lock nut when adjusting backlash of gear- box. ST-926230000 34099PA100 SPANNER Used for measuring the rotating resistance of gear-box assembly.
  • Page 473 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 926420000 PLUG When oil leaks from pinion side of gearbox assembly, remove pipe B from valve housing, attach this tool and check oil leaking points. ST-926420000 926370000 INSTALLER A •...
  • Page 474 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 926400000 GUIDE • Right side of rack when installing rack bush. • Used with GUIDE (927660000). • For LHD model. ST-926400000 927660000 GUIDE • Right side of rack when installing rack bush. •...
  • Page 475 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34099FA110 INSTALLER Used for installing oil seal. • For LHD model. ST34099FA110 34099FA120 INSTALLER AND • Used for installing valve housing oil seal. REMOVER SEAL • Used with INSTALLER SEAL. (34099FA130) •...
  • Page 476 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927490000 INSTALLER A, B, C • Used for installing oil seal into rack assembly. • For RHD model. ST-927490000 927580000 REMOVER • Used for removing back-up ring and oil seal. •...
  • Page 477 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34199AE010 INSTALLER • Used for installing rack oil seal (outer). • For RHD model. ST34199AE010 34099FA060 PUNCH HOLDER • Used for caulking. • For RHD model. ST34099FA060 34099FA070 BASE •...
  • Page 478 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34199AE090 PLUG WRENCH • Used for removing plug. • For RHD model. ST34199AE090 34199AE100 PLUG OIL SEAL • Used for removing plug oil seal. REMOVER • For RHD model. ST34199AE100 34199AE110 PLUG OIL SEAL...
  • Page 479 General Description POWER ASSISTED SYSTEM (POWER STEERING) ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 34199AE130 GEARBOX OIL • Used for installing gearbox oil seal. SEAL INSTALLER • For RHD model. ST34199AE130 PS-22...
  • Page 480 Steering Wheel POWER ASSISTED SYSTEM (POWER STEERING) 2. Steering Wheel C: INSPECTION 1) Check the steering wheel for deformation. If the A: REMOVAL deformation is excessive, replace steering wheel. 1) Disconnect the ground cable from battery. 2) Check the splines on steering wheel for damage. 2) Set the tires to straight-ahead position.

  • Page 481: Universal Joint

    Universal Joint POWER ASSISTED SYSTEM (POWER STEERING) 3. Universal Joint 3) Tighten the bolt. Tightening torque: A: REMOVAL 24 N·m (2.4 kgf-m, 17.4 ft-lb) 1) Remove the steering wheel. <Ref. to PS-23, RE- CAUTION: MOVAL, Steering Wheel.> Excessively large tightening torque of the uni- 2) Make matching mark on the universal joint.
  • Page 482 Universal Joint POWER ASSISTED SYSTEM (POWER STEERING) Service limit: Service limit: Maximum load; 3.8 N (0.39 kgf, 0.86 lb) or less Maximum load; 7.3 N (0.74 kgf, 1.64 lb) or less PS-00034 PS-00037 (1) Yoke (gearbox side) (1) Yoke (Steering column side) Service limit: Maximum load;...
  • Page 483 Tilt Steering Column POWER ASSISTED SYSTEM (POWER STEERING) 4. Tilt Steering Column A: REMOVAL PS-00038 Tilt steering column Universal joint Tightening torque: N·m (kgf-m, ft-lb) T1: 24 (2.4, 17.4) T2: 25 (2.5, 18.1) PS-26...
  • Page 484 Tilt Steering Column POWER ASSISTED SYSTEM (POWER STEERING) 1) Set the vehicle on a lift. B: INSTALLATION 2) Disconnect the ground cable from battery. 1) Set the grommet to toe board. 3) Remove the airbag module. <Ref. to AB-12, RE- MOVAL, Driver’s Airbag Module.>...
  • Page 485 Tilt Steering Column POWER ASSISTED SYSTEM (POWER STEERING) D: ASSEMBLY Insert the combination switch to upper column shaft, and then install the upper column cover. Then route the ignition key harness and combina- tion switch harness between column cover mount- ing bosses.
  • Page 486 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 5. Steering Gearbox [LHD MOD- 10) Remove the one pipe joint at center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning the steering wheel fully clockwise and counterclockwise.
  • Page 487 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) B: INSTALLATION 6) After tightening the castle nut to specified torque, tighten it further within 60° until cotter pin 1) Insert the gearbox into crossmember, being hole is aligned with the slot in nut, and then bend careful not to damage the gearbox boot.
  • Page 488 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 21) After adjusting the toe-in and steering angle, 4) Remove the small clip from boot using pliers, tighten the lock nut on tie-rod end. and then move the boot to tie-rod end side. Tightening torque: 83 N·m (8.5 kgf-m, 61.5 ft-lb) NOTE:...
  • Page 489 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 7) Using the ST, loosen the lock nut. 12) Carefully draw out the input shaft, and then re- move the valve assembly. ST 926230000 SPANNER PS-00089 PS-00117 13) Using a sharp pointed pliers, rotate the rack 8) Tighten the adjusting screw until it no longer stopper in direction of the arrow until end of the cir- tightens.
  • Page 490 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 16) Remove the oil seal from rack. 3) Using the ST, loosen the lock nut. 17) Insert the ST from pinion housing side, and ST 926230000 SPANNER then remove the oil seal using a press. ST 34099FA110 INSTALLER PS-00139 4) Tighten the adjusting screw until it no longer...
  • Page 491 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 8) Slide the dust cover out. 11) Remove the snap ring using snap ring pliers. CAUTION: Be careful not to scratch the pinion and valve assembly. PS-00144 (1) Dust cover 9) Using a press remove the pinion and valve as- PS-00154 sembly from valve housing.
  • Page 492 CAUTION: ST 926390001 COVER & REMOVER Use only SUBARU genuine grease for the gear- box. Specified grease for gearbox: VALIANT GREASE M2 (Part No. 003608001) 1) Apply power steering fluid to a new oil seal.
  • Page 493 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 11) Apply genuine grease to dust cover, and then CAUTION: install the dust cover to valve assembly. • If burrs or nicks are found on this guide and rack shaft portion, remove by filing. •...
  • Page 494 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 15) Temporarily install the rack, and then operate it 21) Loosen the adjusting screw, and then apply liq- from lock to lock two or three times to make it fit in. uid gasket to at least 1/3 of the entire perimeter of Remove the grease blocking air vent hole.
  • Page 495 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 27) Bend the lock washer. 29) Install a new boot band. Using band clamp pli- ers, caulk the boot band until caulking part clear- CAUTION: ance is 2 mm (0.079 in) or less. Be careful not to scratch the rack when bending lock washer.
  • Page 496 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 32) If the tie-rod end was removed, screw in the 2. CONTROL VALVE ASSEMBLY lock nut and tie-rod end to screwed portion of tie- Specified steering grease: rod, and then tighten the lock nut temporarily in a VALIANT GREASE M2 (Part No.
  • Page 497 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 7) Attach the bearing to ST, and then position in 12) Install the ST3 to pinion, and then insert the oil value housing. Using the ST and press, install the seal. Press the oil seal using a press until ST4 con- special bearing in valve housing.
  • Page 498 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 15) Install the snap ring using snap ring pliers. 21) Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then in- NOTE: sert sleeve into steering body. Rotate the snap ring to check for proper installa- Charge the adjusting screw with grease, and then tion.
  • Page 499 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 28) Install the lock nut. While holding the adjusting screw with a wrench, tighten lock nut using ST. ST 926230000 SPANNER Tightening torque (Lock nut): 39 N·m (4.0 kgf-m, 28.9 ft-lb) NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
  • Page 500 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) E: INSPECTION 1. BASIC INSPECTION 1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary. 2) When disassembling, check the inside of gearbox for water. If any water is found, carefully check the boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing.
  • Page 501 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 2. SERVICE LIMIT Left-turn steering: Make a measurement as follows. If it exceeds the Service limit specified service limit, adjust or replace. Direction 0.3 mm (0.012 in) or less NOTE: Direction When making a measurement, vise the gearbox by 0.15 mm (0.0059 in) or less using ST.
  • Page 502 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 5. TURNING RESISTANCE OF GEARBOX Using the ST, measure the gearbox turning resis- tance. ST 34099PA100 SPANNER Service limit Maximum allowable resistance 10.5 N (1.1 kgf, 2.4 lb) or less Difference between right and left turning re- sistance: Less than 20% PS-00105 6.
  • Page 503 Steering Gearbox [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 1) Lift up the vehicle. F: ADJUSTMENT 2) Even if the location of the leak can be easily 1) Adjust the front toe. <Ref. to FS-10, FRONT found by observing the leaking condition, it is nec- WHEEL TOE-IN, INSPECTION, Wheel Align- essary to thoroughly remove the fluid from the sus- ment.>...
  • Page 504 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 6. Steering Gearbox [RHD MOD- 10) Remove the one pipe joint at center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning the steering wheel fully clockwise and counterclockwise.
  • Page 505 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...
  • Page 506 POWER ASSISTED SYSTEM (POWER STEERING) Page General Description ..................2 Steering Wheel..................23 Universal Joint...................24 Tilt Steering Column..................26 Steering Gearbox [LHD MODEL] ..............29 Steering Gearbox [RHD MODEL] .............47 Pipe Assembly [LHD MODEL] ..............64 Pipe Assembly [RHD MODEL]..............72 Oil Pump ....................80 Reservoir Tank..................85 Power Steering Fluid.................86 General Diagnostic Table................87...
  • Page 507 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 6. Steering Gearbox [RHD MOD- 10) Remove the one pipe joint at center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning the steering wheel fully clockwise and counterclockwise.
  • Page 508 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) B: INSTALLATION 6) After tightening the castle nut to the specified tightening torque, tighten it further within 60° until 1) Insert the gearbox into crossmember, being cotter pin hole is aligned with slot in the nut. Fit the careful not to damage the gearbox boot.
  • Page 509 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 21) After adjusting the toe-in and steering angle, 3) Remove the clip on outside of boot using pliers, tighten the lock nut on tie-rod end. and then slide the boot to tie-rod end side. Tightening torque: 83 N·m (8.5 kgf-m, 61.5 ft-lb) NOTE:...
  • Page 510 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 6) Tighten the adjusting screw until it no longer 10) Clean the dirt of input shaft. Remove the dust tightens. cover taking care not to scratch the housing or in- put shaft and allow foreign matter to enter gear box interior.
  • Page 511 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 12) Remove the valve assembly taking care not to 14) Install the ST on valve side of rack and press scratch seal ring and valve housing inner surface. outer side oil seal out taking care not to contact rack with steering body inner surface.
  • Page 512 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 15) Insert the ST from valve side and press back- 17) If the cylinder edge is deformed in a convex up ring and oil seal out. shape, repair using an oil stone. ST 927580000 REMOVER PS-00067...
  • Page 513 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 20) Set the stopper to gear box, and then insert the 22) While fixing the 2-surface width, pull out the oil tip of ST to gear box. seal by rotating nut. CAUTION: Take care not to scratch the gear box inner sur- face.
  • Page 514 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 3) Attach the steering body to ST as shown in the 5) Insert the ST·A with oil seal assembled, through figure. Apply a coat of grease to needle bearing. gear side of rack. Remove the oil seal from ST·A ST 926200000 STAND near piston, and then remove the ST·A from rack.
  • Page 515 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 7) Install the ST on rack and equally apply a thin 9) Make the ST2 pass through rack, and then push coat of grease to the rack and ST, then install the oil in the rack and ST2 using a press until ST1 comes seal.
  • Page 516 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 11) Using the ST, clinch steering body cylinder at a 13) Apply a coat of grease on the gear teeth of point less than 3 mm (0.12 in) from holder. valve assembly, and then attach the valve assem- bly taking care not to scratch oil seal and seal ring.
  • Page 517 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 15) Using the ST, install plug. 18) Apply a coat of grease to the sliding surface of seat pad, sleeve and seating surface of spring, and ST 34199AE090 PLUG WRENCH then insert sleeve into steering body. Tightening torque: Charge the adjusting screw with grease, and then 64 N·m (6.5 kgf-m, 47.0 ft-lb)
  • Page 518 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 24) Tighten the adjusting screw. 33) Caulk the boot so the space inside boot band caulking portion becomes 2 mm (0.08 in) or less. Tightening torque: NOTE: 9.8 N·m (10.0 kgf-m, 7.2 ft-lb) Use a new boot band.
  • Page 519 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 36) If the tie-rod end was removed, screw in the lock nut and tie-rod end to screwed portion of tie- rod, and then tighten the lock nut temporarily in a position as shown in the figure. Installed tie-rod length: L Sedan: 25 mm (0.98 in)
  • Page 520 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) E: INSPECTION 1. BASIC INSPECTION 1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary. 2) When disassembling, check the inside of gearbox for water. If any water is found, carefully check the boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing.
  • Page 521 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 2. SERVICE LIMIT Right-turn steering: Make a measurement as follows. If it exceeds the Service limit specified service limit, adjust or replace. Direction 0.3 mm (0.012 in) or less NOTE: Direction When making a measurement, vise gearbox by us- 0.19 mm (0.0075 in) or less ing ST.
  • Page 522 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 5. TURNING RESISTANCE OF GEARBOX Using the ST, measure gearbox turning resistance. ST 34099PA100 SPANNER Service limit Maximum allowable resistance 10.5 N (1.1 kgf, 2.4 lb) or less Difference between right and left turning resis- tance: Less than 20% PS-00105...
  • Page 523 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 1) Lift up the vehicle. 3) If the steering wheel spokes are not horizontal when wheels are set in the straight ahead position, 2) Even if the location of leak can be easily found by observing leaking condition, it is necessary to and error is more than 5°...
  • Page 524 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 7. Pipe Assembly [LHD MODEL] 4) Remove the clamp E from pipes C and D. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and then remove the jack-up plate.
  • Page 525 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 6) NON-TURBO MODEL 7) TURBO MODEL (1) Remove the air intake duct. <Ref. to (1) Remove the air cleaner. IN(H4SO)-6, REMOVAL, Air Intake Duct.> <Ref. to IN(H4DOTC)-7, REMOVAL, Air Clean- (2) Remove the bolt A. er.>...
  • Page 526 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) B: INSTALLATION 2) Install the coolant filler tank. (Turbo model) 1) Temporarily tighten the two bolts fixing pipe C Tightening torque: and D. (bolt A) T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb) T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb) NOTE: Visually check that the hose between tank and pipe...
  • Page 527 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 3) Temporarily connect the pipe C and D to gear 5) Tighten the clamp E firmly. box. Tightening torque: 7.4 N·m (0.75 kgf-m, 5.4 ft-lb) 6) Tighten the joint nut. Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) 7) Connect the pipes A and B to four pipe joints of gearbox.
  • Page 528 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 13) Finally check clearance between pipes and/or hoses, as shown above. If cruise control actuator-to-power steering hose clearance is less than 10 mm (0.39 in), move the portion (A) secured by clamp to other portion, or bend portion (B) to adjust. PS-00179 (1) High pressure hose (2) No interference is allowed...
  • Page 529 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) C: INSPECTION Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as re- quired. Part name Inspection Remedy • O-ring fitting surface for damage Pipe •...
  • Page 530 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) NOTE: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after main- tenance.
  • Page 531 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) Fluid leaking area Possible cause Corrective action Insufficient tightening of flare nut, catching Loosen and retighten, if ineffective, dirt or the like, damage to flare or flare nut or replace. eye bolt Leakage from connecting portions of pipes and hoses, numbered with (1) Poor insertion of hose, poor clamping...
  • Page 532 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 8. Pipe Assembly [RHD MODEL] 4) Remove the clamp E from pipes C and D. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and then remove the jack-up plate.
  • Page 533 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 6) Non-turbo model 7) Turbo model (1) Remove the air cleaner. (1) Remove the air cleaner. (2) Remove the bolt A. <Ref. to IN(H4DOTC)-7, REMOVAL, Air Clean- er.> (3) Disconnect the pipe C from oil pump. Dis- connect the pipe D from return hose.
  • Page 534 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) B: INSTALLATION 2) Install the coolant filler tank. (Turbo model) 1) Temporarily tighten the two bolts fixing pipe C Tightening torque: and D. (bolt A for Non-turbo model.) T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb) T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb) NOTE: Visually check that the hose between tank and pipe...
  • Page 535 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 3) Temporarily connect the pipe C and D to gear 6) Tighten the joint nut. box. Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) 7) Connect the pipes A and B to four pipe joints of gearbox.
  • Page 536 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 12) Finally check clearance between pipes and/or hoses, as shown in the figure. PS-00122 (1) Clearance between blow-by hose (3) Clearance between side frame and (5) Steering gearbox and pipe: 3 — 5 mm (0.12 — 0.20 in) hose: 15 mm (0.59 in) or more (2) No interference is allowed between (4) Clearance between crossmember...
  • Page 537 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) C: INSPECTION Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as re- quired. Part name Inspection Remedy • O-ring fitting surface for damage Pipe •...
  • Page 538 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) NOTE: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after main- tenance.
  • Page 539 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) Fluid leaking area Possible cause Corrective action Insufficient tightening of flare nut, catching Loosen and retighten, if ineffective, dirt or the like, damage to flare or flare nut or replace. eye bolt Leakage from connecting portions of pipes and hoses, numbered with (1) Poor insertion of hose, poor clamping...
  • Page 540 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) 9. Oil Pump 6) Remove the bolts which install the power steer- ing pump bracket. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the pulley belt cover. 3) Loosen the belt tension adjusting bolt and gen- erator securing bolt, and then remove the power steering pump V-belt.
  • Page 541 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) B: INSTALLATION Tightening torque: 37.3 N·m (3.8 kgf-m, 27.5 ft-lb) 1) Install the oil pump to bracket. (1) Place the oil pump bracket in a vise. Tighten the bushing using a 12.7 mm (1/2″) type 14 mm and 21 mm box wrench until it is in contact with the oil pump mounting surface.
  • Page 542 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) 7) Tighten the bolt of belt tension. Tightening torque: 25 N·m (2.5 kgf-m, 18.1 ft-lb) 8) Install the pulley belt cover. 9) Connect the battery ground cable to battery. 10) Feed the specified power steering fluid. <Ref. to PS-86, Power Steering Fluid.>...
  • Page 543 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) Axial play (Direction • Measure the load during rotation and make a judgment. 0.9 mm (0.035 in) or less PS-00148 PS-00146 (1) Dial indicator (1) Spring balance 2) Ditch deflection of pulley 3. HYDRAULIC PRESSURE Service limit: NOTE: 1.0 mm (0.039 in) or less...
  • Page 544 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) (5) Install the ST3 to end of pipe C removed (4) If it is not within the specified value, replace from pump. the oil pump. (6) Replenish power steering fluid up to the 3) Measure the working pressure.

  • Page 545: Reservoir Tank

    Reservoir Tank POWER ASSISTED SYSTEM (POWER STEERING) 10.Reservoir Tank C: INSPECTION Check the reservoir tank for cracks, breakage, or A: REMOVAL damage. If any cracks, breakage, or damage is 1) Remove the air intake duct. <Ref. to IN(H4SO)- found, replace the reservoir tank. 6, REMOVAL, Air Intake Duct.>...
  • Page 546 Power Steering Fluid POWER ASSISTED SYSTEM (POWER STEERING) 11.Power Steering Fluid C: REPLACEMENT 1) Lift up the vehicle. A: SPECIFICATION 2) Remove the jack up plate. 3) Remove the pipe joint in center of gear box, and Recommended power steering fluid Manufacturer then install the vinyl hose to pipe and joint.
  • Page 547 General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) 12.General Diagnostic Table A: INSPECTION Trouble Possible cause Corrective action • Heavy steering effort in all 1. Pulley belt ranges • Unequal length of pulley belts • Heavy steering effort at • Adhesion of oil and grease stand still •...

  • Page 548: Noise And Vibration

    General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) 1. NOISE AND VIBRATION CAUTION: Don’t keep the relief valve operated over 5 seconds at any time or inner parts of the oil pump may be damaged due to rapid increase of fluid temperature. NOTE: •...
  • Page 549 General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) Trouble Possible cause Corrective action Fix the wrong part causing aera- Fluid aeration tion. Replace the fluid and vent air. Damaged pipe of gearbox Replace the pipe. Sizzling noise (continuous) While engine is running. Abnormal inside of hose or pipe Rectify or replace.
  • Page 550 General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) 2. MEASUREMENT OF STEERING EFFORT Step Check CHECK STEERING EFFORT. Is the steering effort less than Go to step 2. Adjust the back- 1)Stop the vehicle on a concrete road. 29.4 N (3.0 kgf, 6.6 lb)? lash.

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