1996 SUBARU LEGACY Brake caliper

4. Front Strut
A: REMOVAL
G4M0502
1Dust seal

2Strut mount

3Spacer

4Upper spring seat

5Rubber seat

6Dust cover
7Helper

8Coil spring

9Damper strut

10Adjusting bolt

11Self-locking nut
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 20±6 (2.0±0.6, 14.5±4.3)
T2: 54±5 (5.5±0.5, 39.8±3.6)
T3: 152±20 (15.5±2.0, 112±14)
G4M0503
1) Remove wheel.
2) Depress brake pedal and hold it down using a wooden
block etc.
3) Remove union bolts from caliper.
CAUTION:
Use brake hose cap to prevent brake fluid from escap-
ing.
21
4-1SERVICE PROCEDURE
4. Front Strut

G4M0511
7) Pull the piston rod fully upward, and install rubber seat
and spring seat.
NOTE:
Ensure that upper spring seat is positioned with“OUT”
mark facing outward.
8) Install strut mount to the piston rod, and tighten the
self-locking nut temporarily.
CAUTION:
Be sure to use a new self-locking nut.
G4M0507
9) Using hexagon wrench to prevent strut rod from turning,
tighten self-locking nut with ST.
Tightening torque:
54±5 N⋅m (5.5±0.5 kg-m, 39.8±3.6 ft-lb)
ST 927760000 STRUT MOUNT SOCKET
10) Loosen the coil spring carefully.
E: INSTALLATION
1) Install strut mount at upper side of strut to body and
tighten with nuts.
Tightening torque:
20±6 N⋅m (2.0±0.6 kg-m, 14.5±4.3 ft-lb)
2) Connect housing to lower side of strut.
3) Position aligning mark on camber adjusting bolt with
aligning mark on lower side bracket of strut.
CAUTION:

While holding head of adjusting bolt, tighten self-
locking nut.

Be sure to use new self-locking nut.
Tightening torque:
152±20 N⋅m (15.5±2.0 kg-m, 112±14 ft-lb)
4) Install A.B.S. sensor harness to strut. (A.B.S. equipped
models.)
Tightening torque:
152±20 N⋅m (15.5±2.0 kg-m, 112±14 ft-lb)
5) Install brake hose at lower side of strut with clamp.
G4M0503
6) Install union bolts which secure brake caliper to brake
hose.
Tightening torque:
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
CAUTION:
Be sure to bleed air from brake system.
7) Install wheels.
NOTE:
Check wheel alignment and adjust if necessary.
25
4-1SERVICE PROCEDURE
4. Front Strut

G4M0538
7) Models equipped with rear disc brakes:
Remove union bolt from brake caliper.
8) Models equipped with rear drum brakes:
Disconnect brake hose from brake pipe from strut, and
disconnect brake pipe from dram brake.
G4M0539
9) Remove bolts which secure rear strut to housing.
10) Remove nuts securing strut mount to body.
11) Remove strut mount cap.
B: DISASSEMBLY
For disassembly of rear strut, refer to procedures outlined
under front strut as a guide.

C: INSPECTION
Refer to Front Strut 4-1 [W4C0] as a guide for inspection
procedures.
G4M0540
D: ASSEMBLY
Refer to Front Strut 4-1 [W4D0] as a guide for assembly
procedures.
CAUTION:

Install rear strut with “FWD” or “4WD” mark on strut
mount facing outside of vehicle body.

Insert the protrusion of lower rubber seat into the
strut spring seat hole.
41
4-1SERVICE PROCEDURE
9. Rear Strut

E: INSTALLATION
1) Install strut mount cap.
2) Tighten self-locking nut used to secure strut mount to
vehicle body.
CAUTION:
Use a new self-locking nut.
NOTE:
Tighten strut mount and cap as a unit.
Tightening torque:
20±6 N⋅m (2.0±0.6 kg-m, 14.5±4.3 ft-lb)
3) Tighten bolts securing rear strut to housing.
Tightening torque:
196
+39
10N⋅m (20.0+4.0
1.0kg-m, 145+29
7ft-lb)
CAUTION:
Use a new self-locking nut.
4) Models with rear disc brakes:
Tighten brake hose union bolt on brake caliper.
Tightening torque:
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
Models with rear drum brakes:
Connect brake hose to brake pipe.
Tightening torque:
15
+3
2N⋅m (1.5+0.3
0.2kg-m, 10.8+2.2
1.4ft-lb)
5) Insert brake hose clip between brake hose and lower
side of strut.
CAUTION:

Check that hose clip is positioned properly.

Check brake hose for twisting, or excessive tension.

Models equipped with A.B.S.:
Do not subject A.B.S. sensor harness to excessive ten-
sion.
6) Be sure to bleed air from brake system.
7) Lower vehicle and tighten wheel nut.
Tightening torque:
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
8) Sedan:
Install rear seat backrest and rear seat cushion.
Wagon:
Install strut cap of rear quarter trim.
NOTE:
Check wheel alignment and adjust if necessary.
42
4-1SERVICE PROCEDURE
9. Rear Strut

1. Front Axle
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands, and
remove front wheels.
G4M0214
3) Unlock axle nut.
4) Remove axle nut using a socket wrench.
CAUTION:
Be sure to loose and retighten axle nut after removing
wheel from vehicle. Failure to follow this rule may dam-
age wheel bearings.
G4M0215
5) Remove stabilizer link.
G4M0216
6) Remove DOJ from transmission spindle.
7) Remove front drive shaft assembly from hub. If it is hard
to remove, use STs.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
Be careful not to damage oil seal lip when removing
front drive shaft.
When replacing front drive shaft, also replace inner
oil seal.
8) Remove disc brake caliper from housing, and suspend
it from strut using a wire.
9
4-2SERVICE PROCEDURE
1. Front Axle

E: INSTALLATION
1) Install transverse link ball joint to housing.
Tightening torque:
44±6 N⋅m (4.5±0.6 kg-m, 32.5±4.3 ft-lb)
2) While aligning alignment mark on camber adjusting bolt
head, connect housing and strut.
CAUTION:
Use a new self-locking nut.
Tightening torque:
147±15 N⋅m (15±1.5 kg-m, 108±11 ft-lb)
3) Install speed sensor and harness on housing (only
vehicle equipped with A.B.S.).
4) Install disc rotor on hub.
5) Install disc brake caliper on housing.
Tightening torque:
59±10 N⋅m (6±1 kg-m, 43±7 ft-lb)
6) Install front drive shaft.
7) Connect stabilizer link.
G4M0236
8) Install tie-rod end ball joint on housing knuckle arm.
Tightening torque:
27.0±2.5 N⋅m (2.75±0.25 kg-m, 19.9±1.8 ft-lb)
G4M0237
9) While depressing brake pedal, tighten axle nut and lock
it securely.
Tightening torque:
186±20 N⋅m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
Use a new axle nut.
Always tighten axle nut before installing wheel on
vehicle. If wheel is installed and comes in contact with
ground when axle nut is loose, wheel bearings may be
damaged.
Be sure to tighten axle nut to specified torque. Do
not overtighten it as this may damage wheel bearing.
15
4-2SERVICE PROCEDURE
1. Front Axle

G4M0238
10) After tightening axle nut, lock it securely.
11) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque:
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
2. Rear Axle (AWD Model)
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, and remove rear wheel cap and
wheels.
CAUTION:
Be sure to loosen and retighten axle nut after remov-
ing wheel from vehicle. Failure to follow this rule may
damage wheel bearings.
3) Unlock axle nut.
4) Remove axle nut using a socket wrench.
B4M0050A
5) Return parking brake lever and loosen adjusting nut.
(1) Disc brake: Perform steps 6) and 7).
(2) Drum brake: Perform steps 8) through 10).
G4M0240
6) Remove disc brake caliper from back plate, and sus-
pend it from strut using a piece of wire.
7) Remove disc rotor from hub.
NOTE:
If disc rotor seizes up within hub, drive it out by installing
an 8-mm bolt into bolt hole in disc rotor.
16
4-2SERVICE PROCEDURE
1. Front Axle - 2. Rear Axle (AWD Model)

G4M0238
10) After tightening axle nut, lock it securely.
11) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque:
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
2. Rear Axle (AWD Model)
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, and remove rear wheel cap and
wheels.
CAUTION:
Be sure to loosen and retighten axle nut after remov-
ing wheel from vehicle. Failure to follow this rule may
damage wheel bearings.
3) Unlock axle nut.
4) Remove axle nut using a socket wrench.
B4M0050A
5) Return parking brake lever and loosen adjusting nut.
(1) Disc brake: Perform steps 6) and 7).
(2) Drum brake: Perform steps 8) through 10).
G4M0240
6) Remove disc brake caliper from back plate, and sus-
pend it from strut using a piece of wire.
7) Remove disc rotor from hub.
NOTE:
If disc rotor seizes up within hub, drive it out by installing
an 8-mm bolt into bolt hole in disc rotor.
16
4-2SERVICE PROCEDURE
1. Front Axle - 2. Rear Axle (AWD Model)