1996 SUBARU LEGACY door lock

2. REAR DOOR
B5M0058A

1Door outer handle


2Door latch


3Door lock actuator


4Striker


5Rod holder


6Holder remote


7Inner remote ASSY
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4±2.0 (0.65±0.2, 4.7±1.4)
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
T3: 14±4 (1.4±0.4, 10.1±2.9)
9
5-2COMPONENT PARTS
6. Door Lock Assembly

1. Procedure Chart for Removing and
Installing Door and Related Parts
NOTE:
This flow chart shows the main procedures for removing
and installing the door and its related parts. For details,
refer to the text.
DoorDoor lock systemDoor regulator

Door glass

Remove door trim parts, etc.

REMOVALRemove front and rear upper stoppers
and stabilizer (inner).

Remove door.Disconnect joints
between latch, outer
handle, key lock and
remote assembly.Separate door glass from regulator.
Remove guide
channel B.Remove door
glass.
Remove door
lock system.Remove
regulator.
Install door.Install door
lock system.Install regulator.
Install guide
channel.Insert door glass.

Adjust door alignment.Adjust door
lock system.Mount door glass on regulator.

INSTALLATION
AND
ADJUSTMENTAdjust striker.Link latch, outer handle,
key lock and remote
assembly together.Install front and rear upper stoppers
and stabilizer (inner).

Adjust glass position.

Install door trim parts, etc.

Confirm.












12
5-2SERVICE PROCEDURE
1. Procedure Chart for Removing and Installing Door and Related Parts

G5M0486
2. Door
A: REMOVAL AND INSTALLATION
1. DOOR ASSY
1) Remove lower trim and disconnect connectors from
body harness.
2) Place a cloth or a wood block under door to prevent
damage, and support it with a jack.
3) Remove checker pin by driving it upward. Be careful not
to damage door and body.
G5M0385
4) Remove bolts (M8) securing upper and lower hinges to
door, and remove door from hinges.
Tightening torque:
25±3 N⋅m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
5) Remove hinges by loosening hinges mounting bolt (M8)
off of body.
Tightening torque:
29±5 N⋅m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
CAUTION:
Work carefully to avoid damaging door.
6) Installation is in the reverse order of removal.
NOTE:
Apply grease to moving parts of door hinges.
B5M0329A
2. TRIM PANEL
1) Press retainer spring

1with a thin flat bladed screw-
driver and then remove regulator handle

2. (models with-
out power window)
B5M0061A
2) Remove gusset cover
1and three screws.
13
5-2SERVICE PROCEDURE
2. Door

B5M0065
8) Remove regulator installing bolt and guide channel B
installing nut.
9) Remove regulator through lower service hole of door
panel.
10) Installation is in the reverse order of removal.
G5M0394
6. INNER REMOTE
1) Remove trim panel.
2) Remove sealing cover.
3) Disconnect joints of two rods.
4) Unlatch rod holder.
B5M0066A
5) Remove remote holder
1and then remove inner
remote assembly

2.
6) Installation is in the reverse order of removal. Some
special items will be described below.
7) After passing two rods through holder, attach remote
assembly to inner panel.
8) Latch rod holder.
B5M0330A
9) Lock the door and then loosen bolt
1.
10) Lower bell-crank

2and then tighten bolt
2.
NOTE:
If rear door is equipped with child safety lock, check that
child lock lever moves without dragging.
16
5-2SERVICE PROCEDURE
2. Door

7. DOOR LATCH
1) Remove trim panel.
2) Remove inner remote assembly.
3) Remove sealing cover around latch service hole. to 5-2 [W2A3].>
4) Completely close door glass.
B5M0067
5) Remove latch and actuator assembly.
(1) Turn rod holder to disconnect joint between key
lock and rod.
(2) Turn rod holder to disconnect joint between outer
handle and rod.
(3) Turn rod holder to disconnect joint between crank
and rod.
G5M0396
6) Loosen screws securing both latch and actuator, then
remove latch and actuator assembly through service hole
in bottom.
Tightening torque (screw):
6.4±2.0 N⋅m (0.65±0.2 kg-m, 4.7±1.4 ft-lb)
7) Installation is in the reverse order of removal.
Some special items will be described below.
8) Check operation of each part.
9) Check each sliding part for proper lubrication.
CAUTION:
After installation, be sure lock mechanism operates
normally.
17
5-2SERVICE PROCEDURE
2. Door

B5M0068
8. OUTER HANDLE
1) Remove trim panel.
2) Remove sealing cover.
3) Detach door latch rod from outer handle and key lock.
4) Loosen nut securing outer handle and then remove
outer handle from outside.
CAUTION:
Be careful not to damage door.
Installation is in the reverse order of removal.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
B5M0069A
9. KEY LOCK
1) Remove trim panel.
2) Remove sealing cover.
3) Completely close door glass.
4) Remove outer handle.
5) Loosen spring

1securing key lock.
6) Remove key lock from outer handle.
Installation is in the reverse order of removal.
NOTE:
Install so that key slot in key lock comes to center of hole
in outer handle.
B5M0070A
10. GUSSET
NOTE:
Be sure window is all the way down.
1) Remove trim panel.
2) Remove door rearview mirror.
3) Remove sealing cover.
4) Remove bolts and nuts which secure gusset.
5) Lift out gusset

1.
To install, reverse the above removal procedures.
18
5-2SERVICE PROCEDURE
2. Door

G5M0551
9) General precautions in handling rear gate gas stay.
CAUTION:
Do not attempt to disassemble gas stay because its
cylinder is filled with gas.
Before discarding gas stay, place it at a slight angle
with the cylinder body side facing up and drilla2to3
mm (0.08 to 0.12 in) dia. hole to completely discharge
the content. (Gas is odorless, colorless and harmless;
however, metal powder may come out of the hole.)
G5M0491
It is good practice to place a vinyl sack over it before
drilling the hole because oil may spurt out. Be careful
to prevent vinyl cover from becoming entangled on the
drill.
Be careful not to scratch the exposed section of
piston rod or allow oil or paint to come in contact with
it.
Do not attempt to rotate the extended piston rod.
10) Installation is in the reverse order of removal.
CAUTION:
Be sure to add sealer to hinge.
When installing rear gate, be careful not to damage
coating on body and rear gate.
G5M0404
2. LATCH
1) Remove trim panel.
2) Disengage rod from holder (= key cylinder).
3) Remove bolts from auto-door lock actuator.
4) Remove bolts from latch, and detach latch.
5) Disconnect rear gate switch connector.
6) Disconnect auto-door lock actuator connector.
7) Detach latch.
8) Installation is in the reverse order of removal.
B5M0083
3. OUTER HANDLE
1) Remove trim panel.
2) Disconnect rod from outer handle.
3) Remove two nuts used to hold outer handle to the
inside of rear gate, and detach outer handle.
CAUTION:
Be careful not to damage packing when removing
outer handle.
4) Installation is in the reverse order of removal.
28
5-2SERVICE PROCEDURE
3. Rear Gate

B6M0070A
4. DOOR SWITCH
1) Remove rubber boot of door switch.
2) Remove screw which secures door switch to body.
3) Remove door switch while disconnecting connector.
5. TRUNK ROOM LIGHT SWITCH (SEDAN)
Refer to 5-1 [W2A3] as for removal and installation of trunk
room light switch which is installed in trunk lid lock.
6. LUGGAGE ROOM LIGHT SWITCH (WAGON)
Refer to 5-2 [W3A2] as for removal and installation of lug-
gage room light switch which is installed in rear gate lock.
B6M0071
B: INSPECTION
1. DOOR SWITCH
Move switch and check continuity between terminal of door
switch and switch body.
Switch position Terminal Switch body
Open (ON)
Push in (OFF)
B6M0072A
2. TRUNK ROOM LIGHT SWITCH (SEDAN)
Move switch and check continuity between terminals of
trunk room light switch.
Terminal
Switch position12
Open (ON)
Push in (OFF)
B6M0073A
3. LUGGAGE ROOM LIGHT SWITCH (WAGON)
Move switch and check continuity between terminals of
luggage room light switch.
Terminal
Switch position12
Open (ON)
Push in (OFF)
21
6-2SERVICE PROCEDURE
8. Room Light and Door Switch