Subaru 2004 LEGACY User manual

FUJI HEAVY INDUSTRIES LTD. G2320GE6

2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

CHASSIS SECTION

This service manual has been prepared

to provide SUBARU service personnel

with the necessary information and data

for the correct maintenance and repair

of SUBARU vehicles.

This manual includes the procedures

for maintenance, disassembling, reas-

sembling, inspection and adjustment of

components and diagnostics for guid-

ance of experienced mechanics.

Please peruse and utilize this manual

fully to ensure complete repair work for

satisfying our customers by keeping

their vehicle in optimum condition.

When replacement of parts during

repair work is needed, be sure to use

SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are

based on the latest product information

available at the time of publication

approval.

FRONT SUSPENSION FS

REAR SUSPENSION RS

WHEEL AND TIRE SYSTEM WT

DIFFERENTIALS DI

TRANSFER CASE TC

DRIVE SHAFT SYSTEM DS

ABS ABS

ABS (DIAGNOSTICS) ABS(diag)

VEHICLE DYNAMICS CONTROL (VDC) VDC

VEHICLE DYNAMICS CONTROL (VDC)

(DIAGNOSTICS) VDC(diag)

BRAKE BR

PARKING BRAKE PB

POWER ASSISTED SYSTEM

(POWER STEERING) PS

BRAKE BR

Page

1. General Description ....................................................................................2

2. Front Brake Pad........................................................................................16

3. Front Disc Rotor........................................................................................19

4. Front Disc Brake Assembly.......................................................................20

5. Rear Brake Pad.........................................................................................25

6. Rear Disc Rotor.........................................................................................26

7. Rear Disc Brake Assembly .......................................................................28

8. Master Cylinder.........................................................................................30

9. Brake Booster ...........................................................................................32

10. Brake Fluid................................................................................................36

11. Air Bleeding...............................................................................................38

12. Brake Hose ...............................................................................................40

13. Brake Pipe.................................................................................................42

14. Brake Pedal...............................................................................................43

15. Stop Light Switch ......................................................................................45

16. Diagnosis ..................................................................................................47

BR-2

BRAKE General Description

1. General Description

A: SPECIFICATION

NOTE:

Refer to “PB” section for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General Descrip-

tion.>

Model 2.0 i, 2.5 i OUTBACK 2.5 i,

OUTBACK 3.0 R 2.0 GT, 3.0 R

Front disc

brake

Size 15-inch type 16-inch type 17-inch type

Type Disc (Floating type, ventilated)

Effective disc diameter mm (in) 228 (8.98) 244 (4.61) 261 (10.28)

Disc thickness ×Outer

diameter mm (in) 24 ×277 (0.94 ×10.91) 24 ×294 (0.94 ×11.57) 30 ×316 (1.18 ×12.44)

Effective cylinder diameter 42.8 (1.685) ×2

Pad dimensions

(length ×width ×thick-

ness) mm (in) 117.8 ×50.5 ×11.0 (4.638 ×1.988 ×0.433) 130.0 ×53.5 ×11.0

(5.118 ×2.106 ×0.433)

Clearance adjustment Automatic adjustment

Rear disc

brake

Size 15-inch type

Type Disc (Floating type, solid) Disc (Floating type, ven-

tilated)

Effective disc diameter mm (in) 238 (9.37) 254 (10.0)

Disc thickness ×Outer

diameter mm (in) 10 ×274 (0.39 ×10.79) 18 ×290 (0.71 ×11.42)

Effective cylinder

diameter mm (in) 38.1 (1.500)

Pad dimensions

(length ×width ×thick-

ness) mm (in) 92.0 ×33.0 ×9.0 (3.622 ×1.299 ×0.354) 82.4 ×33.7 ×9.0

(3.244 ×1.327 ×0.354)

Clearance adjustment Automatic adjustment

Master

cylinder

Type Tandem

Effective diameter mm (in) 23.8 (15/16)

Reservoir type Sealed type

Brake fluid reservoir

capacity cm3

(cu in) 205 (12.51)

Brake

booster Type Vacuum suspended

Effective diameter mm (in) 208 + 229 (8.19 + 9.02)

Brake line Dual circuit system

Brake fluid

CAUTION:

• Avoid mixing brake fluid of different

brands to prevent fluid performance from

degrading.

• When brake fluid is supplemented, be

careful not to allow any dust into the reser-

voir.

• Use fresh SUBARU genuine brake fluid

when replacing or refilling the fluid.

FMVSS No. 116, DOT3

BR-3

BRAKE

General Description

Item Standard value Limit

Front brake

Pad thickness

mm (in)

Except 17-inch

type 11 (0.43) 1.5 (0.059)

17-inch type 11 (0.43) 1.5 (0.059)

Disc thickness

mm (in)

Except 17-inch

type 24 (0.94) 22 (0.87)

17-inch type 30 (1.18) 28 (1.10)

Disc runout mm (in) — 0.05 (0.0020)

Rear brake (Disc

type)

Pad thickness

mm (in) Solid disc 9.0 (0.354) 1.5 (0.059)

Ventilated disc 9.0 (0.354) 1.5 (0.059)

Disc thickness

mm (in) Solid disc 10 (0.39) 8.5 (0.335)

Ventilated disc 18 (0.71) 16 (0.63)

Disc runout mm (in) — 0.05 (0.0020)

Parking brake Inside diameter mm (in) 170 (6.69) 171 (6.73)

Lining thickness mm (in) 3.2 (0.126) 1.5 (0.059)

Lever stroke 5 — 6 notches/200 N (20 kgf, 45 lb)

Brake pedal force

N (kgf, lb) Fluid pressure kPa (kg/cm2, psi)

15-inch type 16-inch type 17-inch type

Brake

Booster

Brake fluid pressure without

engine running 147 (15, 33) 545 (6, 79)

294 (30, 66) 1,564 (16, 227)

Brake fluid pressure with

engine running and vacuum

at 66.7 kPa (500 mmHg,

19.69 inHg)

147 (15, 33) 6,003 (61, 871) 5,381 (55, 780) 4,963 (51, 720)

294 (30, 66) 11,273 (115, 1,635) 10,982 (112, 1,593) 10,055 (103, 1,458)

Brake pedal Free play

mm (in) 0.5 — 2 (0.02 — 0.08)

[When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lb).]

BR-4

BRAKE General Description

B: COMPONENT

1. FRONT DISK BRAKE

• Except for EC, EK, OUTBACK model

(A) 15, 16-inch type (7) Piston boot (16) Disc cover

(B) 17-inch type (8) Lock pin (Yellow) (17) Bushing

(9) Support

(1) Caliper body (10) Pad clip Tightening torque: N

⋅

m (kgf-m, ft-lb)

(2) Air bleeder screw (11) Outer shim T1: 8 (0.8, 5.8)

(3) Guide pin (Green) (12) Inner shim T2: 27 (2.8, 19.9)

(4) Pin boot (13) Pad (Outside) T3: 80 (8.2, 59)

(5) Piston seal (14) Pad (Inside)

(6) Piston (15) Disc rotor

BR-00332

(1)

(2)

(3)

(4)

(17)

(10)

(11)

(12)

(16)

(A)

(B)

(13)

(14)

(15)

(5)

(6)

(7)

(9)

(8)

(11)

(12)

(13)

(14)

(13)

BR-5

BRAKE

General Description

• EC, EK, OUTBACK model

(1) Caliper body (9) Support (17) Bushing

(2) Air bleeder screw (10) Pad clip

(3) Guide pin (Green) (11) Outer shim Tightening torque: N

⋅

m (kgf-m, ft-lb)

(4) Pin boot (12) Inner shim T1: 8 (0.8, 5.8)

(5) Piston seal (13) Pad (Outside) T2: 27 (2.8, 19.9)

(6) Piston (14) Pad (Inside) T3: 80 (8.2, 59)

(7) Piston boot (15) Disc rotor

(8) Lock pin (Yellow) (16) Disc cover

BR-00373

(1)

(2)

(3)

(4)

(17)

(10)

(11)

(12)

(16)

(13)

(14)

(15)

(5)

(6)

(7)

(9)

(8)

BR-6

BRAKE General Description

2. REAR DISC BRAKE

(1) Caliper body (15) Shoe hold-down pin (29) Adjuster

(2) Air bleeder screw (16) Cover (30) Shoe hold-down cup

(3) Guide pin (Green) (17) Back plate (31) Shoe hold-down spring

(4) Pin boot (18) Retainer (32) Disc rotor (Solid type)

(5) Piston seal (19) Spring washer (33) Disc rotor (Ventilated type)

(6) Piston (20) Parking brake lever (34) Bolt (For solid disc brake)

(7) Piston boot (21) Parking brake shoe (Secondary) (35) Bolt (For ventilated disc brake)

(8) Support (22) Parking brake shoe (Primary)

(9) Lock pin (Yellow) (23) Strut Tightening torque: N

⋅

m (kgf-m, ft-lb)

(10) Bushing (24) Strut shoe spring T1: 8 (0.8, 5.8)

(11) Pad clip (25) Shoe guide plate T2: 27 (2.8, 19.9)

(12) Inner pad (26) Secondary shoe return spring T3: 37 (3.8, 27.5)

(13) Outer pad (27) Primary shoe return spring T4: 53 (5.4, 39.1)

(14) Shim (28) Adjusting spring

BR-00374

(1)

(2)

(3)

(4)

(10)

(14)

(11)

(18)

(19)

(20) (21)

(22)

(23)

(24)

(25)

(26)

(27)

(28) (29)

(30)

(31)

(32)

(12)

(13)

(14)

(17)

(16)

(5)

(6)

(7)

(8)

(9)

(33)

(15)

(35)

(34)

(14)

BR-7

BRAKE

General Description

3. MASTER CYLINDER

• LHD model

(1) Cap (6) Secondary piston (11) O-ring

(2) Filter (7) Cylinder body

(3) Reservoir tank (8) Cylinder pin Tightening torque: N

⋅

m (kgf-m, ft-lb)

(4) C-ring (9) Seal T: 13 (1.3, 9.6)

(5) Primary piston (10) Pin

BR-00371

(1)

(2)

(3)

(7)

(8)

(9)

(10)

(4)

(11)

(5)

(6)

BR-8

BRAKE General Description

• RHD model

(1) Cap (6) Secondary piston (11) O-ring

(2) Filter (7) Cylinder body

(3) Reservoir tank (8) Cylinder pin Tightening torque: N

⋅

m (kgf-m, ft-lb)

(4) C-ring (9) Seal T: 13 (1.3, 9.6)

(5) Primary piston (10) Pin

BR-00334

(1)

(2)

(3)

(7)

(8)

(9)

(10)

(4)

(11)

(5)

(6)

BR-9

BRAKE

General Description

4. FRONT BRAKE PIPES AND HOSE

• LHD model

(A) Model with ABS (5) Clamp Tightening torque: N

⋅

m (kgf-m, ft-lb)

(B) Model with Vehicle dynamics con-

trol (VDC) (6) Gasket T1: 15 (1.5, 10.8)

(7) ABS control module and hydraulic

control unit (ABSCM&H/U) T2: 18 (1.8, 13.0)

T3: 19 (1.9, 14.0)

(1) Front brake pipe ASSY (8) Bracket T4: 33 (3.4, 24.3)

(2) Two-way connector (9) Master cylinder

(3) Front brake hose RH (10) VDC control module & hydraulic

control unit (VDCCM&H/U)

(4) Front brake hose LH

BR-00372

(8) (2)

(3)

(5)

(6)

(4)

(7)

(6)

(5)

(8) (2)

(3)

(5)

(6)

(4)

(10)

(6)

(5)

(A)

(B)

(1)

(9)

(1)

(9)

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