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

PARKING BRAKE PB
Page
1. General Description ....................................................................................2
2. Parking Brake Lever....................................................................................5
3. Parking Brake Cable...................................................................................6
4. Parking Brake Assembly (Rear Disc Brake) ...............................................7
5. General Diagnostic Table..........................................................................10

PB-2
PARKING BRAKE General Description
1. General Description
A: SPECIFICATION
Type Mechanical on rear brakes, drum in disc
Effective drum
diameter mm (in) 170 (6.69)
Lining dimensions
(length ×width ×
thickness) mm (in) 163.1 ×30.0 ×3.2
(6.421 ×1.181 ×0.126)
Clearance adjustment Manual adjustment
Lever stroke notches/N (kgf, lb) 5 to 6/200 (20.4, 45)

PB-3
PARKING BRAKE
General Description
B: COMPONENT
1. PARKING BRAKE (REAR DISC BRAKE)
(1) Back plate (7) Strut spring (13) Adjuster
(2) Retainer (8) Strut (14) Shoe hold-down cup
(3) Spring washer (9) Shoe guide plate (15) Shoe hold-down spring
(4) Lever (10) Primary return spring (16) Shoe hold-down pin
(5) Parking brake shoe (Primary) (11) Secondary return spring (17) Adjusting hole cover
(6) Parking brake shoe (Secondary) (12) Adjusting spring
PB-00048
(16)
(10)
(13)
(11)
(9)
(6)
(2)
(1)
(17)
(3)
(4)
(7)
(8)
(14)
(15)
(12)
(5)

PB-4
PARKING BRAKE General Description
2. PARKING BRAKE CABLE
C: CAUTION
• Wear work clothing, including a cap, protective
goggles, and protective shoes during operation.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
• 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.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or rigid racks at the specified
points.
• Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.
• Keep grease etc. away from parking brake
shoes.
(1) Parking brake lever (6) Clamp Tightening torque: N ⋅ m (kgf-m, ft-lb)
(2) Parking brake switch (7) Parking brake cable RH T1: 18 (1.8, 13.0)
(3) Adjusting nut (Self-locking nut) (8) Clamp T2: 33 (3.4, 24.3)
(4) Equalizer (9) Parking brake cable LH
(5) Bracket
PB-00056
T1
T2
T1
T1
T1
(5)
(6)
(7)
(8)
(9)
(8)
T2
T1
T1
(1) (3)
T1
(2) (4)

PB-5
PARKING BRAKE
Parking Brake Lever
2. Parking Brake Lever
A: REMOVAL
1) Set the wheel stoppers to tires.
2) Remove the console box.
3) Disconnect the parking brake switch connector.
4) Remove the parking cable adjusting nut (self-
locking nut).
5) Remove the parking brake lever.
B: INSTALLATION
1) Install in the reverse order of removal.
Tightening torque:
Parking brake lever
18 N
⋅ m (1.8 kgf-m, 13.0 ft-lb)
2) Install a new adjusting nut (self-locking nut).
3) Adjust the lever stroke. <Ref. to PB-5, ADJUST-
MENT, Parking Brake Lever.>
C: INSPECTION
1) Operate the parking brake lever 3 to 4 times and
return the lever fully.
2) While pulling the parking brake lever upward,
count the notches.
Lever stroke:
5 to6 notcheswhen pulled with a forceof 200
N (20.4 kgf, 45 lb)
If it is not within the specified value, adjust the park-
ing brake. <Ref. to PB-9, ADJUSTMENT, Parking
Brake Assembly (Rear Disc Brake).>
D: ADJUSTMENT
Adjust the parking lever stroke. <Ref. to PB-9, LE-
VER STROKE, ADJUSTMENT, Parking Brake As-
sembly (Rear Disc Brake).>
PB-00053

PB-6
PARKING BRAKE Parking Brake Cable
3. Parking Brake Cable
A: REMOVAL
1) Remove the rear seat cushion.
2) Remove the console box.
3) Remove the parking cable adjusting nut (self-
locking nut).
4) Remove the parking brake lever. <Ref. to PB-5,
REMOVAL, Parking Brake Lever.>
5) Roll up the floor mat and remove the clamps.
6) Remove the inner cable end from equalizer.
7) Lift-up the vehicle, and then remove the rear
wheels.
8) Remove the parking brake cable from rear
brake. <Ref. to PB-7, REMOVAL, Parking Brake
Assembly (Rear Disc Brake).>
9) Remove the clamp from rear brake.
10) Remove the cable clamp from rear arm brack-
et.
11) Remove the cable clamp from rear floor.
12) Remove the cable assembly.
B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Be sure to pass the cable through the cable guide
inside tunnel.
2) Adjust the lever stroke. <Ref. to PB-5, ADJUST-
MENT, Parking Brake Lever.>
C: INSPECTION
Check and replace the removed cable if damaged,
rusty or faulty.
1) Check the cable for smooth operation.
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends and
cracks.
4) Check the boot for damage, cracks and corro-
sion.
(1) Equalizer
(2) Inner cable end
PB-00043
PB-0000
8
PB-00026

PB-7
PARKING BRAKE
Parking Brake Assembly (Rear Disc Brake)
4. Parking Brake Assembly
(Rear Disc Brake)
A: REMOVAL
1) Release the parking brake.
2) Remove the two mounting bolts and remove the
brake caliper assembly.
3) Suspend the brake caliper assembly so that the
hose is not stretched.
4) Remove the disc rotor.
NOTE:
If the disc rotor is difficult to remove, try the follow-
ing two methods in order.
(1) Turn the adjusting screw using a flat tip
screwdriver until the brake shoe gets away
enough from the disc rotor.
(2) If the disc rotor seizes up within hub, drive
out the disc rotor by pushing two 8 mm bolts in
holes B on rotor.
5) Remove the shoe return spring from parking
brake assembly.
6) Remove the front shoe hold down spring and
pin.
7) Remove the strut and strut spring.
8) Remove the adjuster assembly from parking
brake assembly.
9) Remove the brake shoe.
10) Remove the rear shoe hold down spring and
pin with pliers.
11) Remove the parking brake cable from lever.
12) Using a flat tip screwdriver, raise the retainer.
Remove the parking lever and washer from brake
shoe.
(1) Adjuster
(2) Adjusting hole cover (rubber)
(3) Flat tip screwdriver
(4) Back plate
BR-00346
(1)
(4)
(2)
(3)
BR-0015
5
(1) Parking brake cable
(2) Lever
AB
BR-0003
6
PB-00028
PB-0001
4

PB-8
PARKING BRAKE Parking Brake Assembly (Rear Disc Brake)
B: INSTALLATION
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. 003602002)
• Six contact surfaces of shoe rim and back plate
packing
• Contact surface of shoe wave and anchor pin
• Contact surface of lever and strut
• Contact surface of shoe wave and adjuster as-
sembly
• Contact surface of shoe wave and strut
• Contact surface of lever and shoe wave
2) Insert the primary side brake shoe into anchor
pin groove.
3) Secure the brake shoe with the shoe hold-down
pin and cup.
4) Install the plate to anchor pin, and then assem-
ble the primary return spring to anchor pin.
5) Install the parking brake cable to parking brake
lever.
6) Assemble the strut and adjuster, and then se-
cure the secondary side brake shoe with shoe hold-
down pin and cup.
NOTE:
• Install the strut spring of both right and left wheel
facing vehicle front.
• Install the adjuster assembly with screw on left
side.
7) Install the secondary return spring and adjusting
spring.
8) Adjust the parking brake. <Ref. to PB-9, AD-
JUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>
9) Drive the vehicle for parking brake lining “break-
in”.(1) Drive the vehicle at about 35 km/h (22
MPH).
(2) With the parking brake release button
pushed in, pull the parking brake lever gently.
(3) Drive the vehicle for about 200m (0.12 mile)
in this condition.
(4) Wait 5 to 10 minutes for the parking brake to
cool down.
Repeat once more from step (1).
(5) After breaking-in, re-adjust the parking
brakes.
(1) Primary return spring
(2) Anchor pin
(3) Plate
(4) Primary shoe
(5) Shoe hold-down pin and shoe hold-down cup
PB-0003
9
(1)
(4)
(5)
(2)
(3)
(1) LH
(1) Lever
(2) Secondary brake shoe
(3) Strut spring
(4) Strut
(5) Return spring
(6) Adjuster
(7) Shoe hold-down cup
(8) Adjusting spring
PB-0001
6
PB-0001
7
(1) (2)
(4)
(3)
(5)
(7)
(8) (6)

PB-9
PARKING BRAKE
Parking Brake Assembly (Rear Disc Brake)
C: INSPECTION
1) Measure the brake disc rotor inside diameter. If
the disc is scored or worn, replace the brake disc
rotor.
Disc rotor inside diameter:
Standard:
170 mm (6.69 in)
Service limit:
171 mm (6.73 in)
2) Measure the lining thickness. If it exceeds the
limit, replace shoe assembly.
Lining thickness:
Standard:
3.2 mm (0.126 in)
Service limit:
1.5 mm (0.059 in)
NOTE:
Replace the right and left brake shoe as a set.
D: ADJUSTMENT
1. SHOE CLEARANCE
1) Return the parking brake lever fully.
2) Remove the adjusting hole cover from back
plate.
3) Turn the adjusting screw using a flat tip screw-
driver until the brake shoe is in close contact with
disc rotor.
4) Turn back (downward) the adjusting screw 3 to 4
notches.
CAUTION:
Check there is no brake drag.
5) Install the adjusting hole cover to back plate.
6) Adjust the parking lever stroke. <Ref. to PB-9,
LEVER STROKE, ADJUSTMENT, Parking Brake
Assembly (Rear Disc Brake).>
2. LEVER STROKE
1) Adjust the shoe clearance before lever stroke
adjustment. <Ref. to PB-9, SHOE CLEARANCE,
ADJUSTMENT, Parking Brake Assembly (Rear
Disc Brake).>
2) Remove the parking lever cover.
3) Operate the parking brake lever 3 to 4 times.
4) Turn the adjusting nut until lever stroke is at the
specification.
Lever stroke:
5 to 6 notches when pulled witha forceof 200
N (20.4 kgf, 45 lb)
5) Check there is no brake drag.
6) Install the parking lever cover.
(1) Adjusting screw
(2) Adjusting hole cover (rubber)
(3) Flat tip screwdriver
(4) Back plate
(1)
(4)
(2)
(3)
PB-0003
2
(1) Adjusting nut (Self-locking nut)
PB-00054
(1)

PB-10
PARKING BRAKE General Diagnostic Table
5. General Diagnostic Table
A: INSPECTION
Symptom Possible cause Remedy
Brake drag
Parking brake lever is maladjusted. Adjustment.
Parking brake cable does not move. Repair or replace.
Parking brake shoe clearance is maladjusted. Adjustment.
Return spring is faulty. Replace.
Noise from brake Return spring is faulty. Replace.
Shoe hold-down spring is faulty. Replace.