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)
(4)
(17)
(10)
(11)
(11)
(12)
(12)
(16)
(A)
(B)
(13)
(14)
(15)
(5)
(6)
(7)
(9)
(8)
T2
T3
(11)
(11)
(12)
(12)
(13)
(14)
(13)
T1

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)
(4)
(17)
(10)
(11)
(11)
(12)
(16)
(13)
(14)
(15)
(5)
(6)
(7)
(9)
(8)
T2
T3
T1

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)
(4)
(10)
(14)
(11)
(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)
T2
T4
T1
(33)
T3
(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
T
(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
T
(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
T1
T2
T4
T2
T2
T2
T4
T1
T1
(8) (2)
(3)
(5)
(6)
(4)
(7)
(6)
(5)
T1
T2
T4
T2
T2
T2
T4
T3
T3
(8) (2)
(3)
(5)
(6)
(4)
(10)
(6)
(5)
(A)
(B)
T1
T1
T1
(1)
(9)
T3
T1
T3
(1)
(9)

BR-10
BRAKE General Description
• RHD model
(A) Model with ABS (6) Gasket Tightening torque: N ⋅ m (kgf-m, ft-lb)
(B) Model with VDC (7) ABS control module and hydraulic
control unit (ABSCM&H/U) T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
(1) Front brake pipe ASSY (8) Bracket T3: 19 (1.9, 14.0)
(2) Two-way connector (9) Master cylinder T4: 33 (3.4, 24.3)
(3) Front brake hose RH (10) VDC control module & hydraulic
control unit (VDCCM&H/U)
(4) Front brake hose LH
(5) Clamp
BR-00336
T1
T1
T1
T1
T2
T4
T2
T2
T2
T4
T1
T1
(1)
(8) (2)
(9)
(3)
(5)
(6)
(4)
(7)
(6)
(5)
T1
T3
T3
T1
T2
T4
T2
T2
T2
T4
T3
T3
(1)
(8) (2)
(9)
(3)
(5)
(6)
(4)
(10)
(6)
(5)
(A)
(B)

BR-11
BRAKE
General Description
5. CENTER AND REAR BRAKE PIPES AND HOSE
(1) Center brake pipe ASSY (7) Rear brake pipe LH Tightening torque: N ⋅ m (kgf-m, ft-lb)
(2) Two-way connector (8) Rear brake hose rear RH T1: 15 (1.5, 10.8)
(3) Rear brake pipe ASSY (9) Rear brake hose rear LH T2: 18 (1.8, 13.0)
(4) Rear brake hose RH (10) Clamp T3: 33 (3.4, 24.3)
(5) Rear brake hose LH (11) Gasket
(6) Rear brake pipe RH (12) Bracket
BR-00337
(1)
T1
T1
T2
T1
T2
T3
T1
T3
T3
T3
T1
T2
T2
T1
(2)
(3)
(5)
(7)
(9)
(4)
(6)
(8)
(10)
(10)
(10)
(10)
(10)
(11)
(11)
(11)
(11)
(10)
T1
(12)

BR-12
BRAKE General Description
6. BRAKE BOOSTER
(1) Brake booster
BR-00335
(1)

BR-13
BRAKE
General Description
7. BRAKE PEDAL
• LHD MT model
(1) Brake pedal ASSY (4) Clutch pedal Tightening torque: N ⋅ m (kgf-m, ft-lb)
(2) Stop light switch (5) Clutch pedal pad T1: 8 (0.8, 5.8)
(3) Brake pedal pad (6) Clutch switch T2: 18 (1.8, 13.0)
BR-00375
T2
(5)
(4)
(3)
(2)
(6)
(1)
T2
T2
T1
T1
T2

BR-14
BRAKE General Description
• LHD AT model, RHD model
(1) Brake pedal ASSY (3) Brake pedal pad Tightening torque: N ⋅ m (kgf-m, ft-lb)
(2) Stop light switch T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
BR-00338
T2
T1
T2 T1
(1)
(2)
(3)

BR-15
BRAKE
General Description
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.
• Use SUBARU genuine grease etc. or equivalent.
Do not mix grease, etc. with that of another grade
or from other manufacturers.
• 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.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or rigid racks at the specified
points.
D: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME REMARKS
Snap ring pliers Used for removing and installing snap ring.

BR-16
BRAKE Front Brake Pad
2. Front Brake Pad
A: REMOVAL
1. 15-INCH TYPE
1) Lift-up the vehicle and remove the front wheels.
2) Remove the caliper bolt.
3) Raise the caliper body and support it.
NOTE:
Do not disconnect the brake hose from caliper
body.
4) Remove the pad.
NOTE:
If the brake pad is difficult to remove, proceed as
follows:
(1) Remove the caliper body from support.
(2) Remove the support.
(3) Place the support in a vise between wooden
blocks.
(4) Attach a rod of less than 12 mm (0.47 in) di-
ameter to the shaded area of the brake pad, and
strike the rod with a hammer to drive brake pad
out of place.
2. 16-INCH TYPE
Refer to 15-inch type. <Ref. to BR-16, 15-INCH
TYPE, REMOVAL, Front Brake Pad.>
3. 17-INCH TYPE
Refer to 15-inch type. <Ref. to BR-16, 15-INCH
TYPE, REMOVAL, Front Brake Pad.>
B: INSTALLATION
1. 15-INCH TYPE
1) Apply a thin coat of Molykote M7439 to the pad
clip.
2) Apply a thin coat of Molykote AS880N (Part No.
K0779YA010) to the frictional portion between pad
and pad inner shim.
(1) Support
(2) Wooden block
BR-00339
BR-0001
2
(1)
(2) BR-0001
3
BR-0001
4
BR-00340
BR-00238

BR-17
BRAKE
Front Brake Pad
3) Apply a thin coat of Molykote AS880N (Part No.
K0779YA010) to the three frictional portions be-
tween inner shim and outer shim of outer pads.
4) Install the pad on support.
5) Install the caliper body on support.
Tightening torque:
27 N
⋅ m (2.8 kgf-m, 19.9 ft-lb)
2. 16-INCH TYPE
Refer to 15-inch type. <Ref. to BR-16, 15-INCH
TYPE, INSTALLATION, Front Brake Pad.>
3. 17-INCH TYPE
1) Apply a thin coat of Molykote M7439 to the pad
clip.
2) Apply a thin coat of Molykote AS880N (Part No.
K0779YA010) to the frictional portion between pad
and pad inner shim.
3) Apply a thin coat of Molykote AS880N (Part No.
K0779YA010) to the three frictional portions be-
tween inner shim and outer shim of outer pads.
4) Install the pad on support.
NOTE:
Install the pad indicator in proper direction.
CAUTION:
• Correctly install the pad return spring to sup-
porting surface of pad clip as shown in the fig-
ure.
BR-00341
BR-00340
BR-00238
(1) LH −IN
(2) LH −OUT
(3) RH −IN
(4) RH −OUT
(5) Pad indicator
(6) Pad return spring
BR-00341
BR-00342
(5)
(6)
(6)
(1)
(2)
(3)
(4) (5)
(6)
(6)

BR-18
BRAKE Front Brake Pad
• When the pad return spring is deformed or
damaged, replace the brake pad with new one.
5) Install the caliper body on support.
Tightening torque:
27 N
⋅ m (2.8 kgf-m, 19.9 ft-lb)
C: INSPECTION
1. 15-INCH AND 16-INCH TYPE
Check the pad thickness A.
NOTE:
• Always replace the pads for both right and left
wheels at the same time.
• Also replace the pad clips if they are twisted or
worn.
• Replace the pad if there is oil or grease on it.
2. 16-INCH TYPE
Refer to 15-inch type. <Ref. to BR-18, 15-INCH
AND 16-INCH TYPE, INSPECTION, Front Brake
Pad.>
3. 17-INCH TYPE
Check the pad thickness A.
NOTE:
• Always replace the pads for both right and left
wheels at the same time.
• Replace the pad if there is oil or grease on it.
(1) Pad return spring
(2) Supporting surface of pad clip
Pad thicknessmm (in) Standard value 11 (0.43)
Wear limit 1.5 (0.059)
BR-00343
(1)
(2)
BR-00360
A
Pad thickness mm (in)
Standard
value 11 (0.43)
Wear limit 1.5 (0.059)
BR-00360
A

BR-19
BRAKE
Front Disc Rotor
3. Front Disc Rotor
A: REMOVAL
1. 15-INCH TYPE
1) Lift-up the vehicle, and remove the front wheels.
2) Remove the caliper body and the support from
housing, and suspend it from strut using a wire.
3) Remove the disc rotor.
NOTE:
If the disc rotor seizes up within hub, drive the disc
rotor out by pushing with an 8 mm bolt in holes B on
the rotor.
4) Clean mud and foreign particles from the caliper
body assembly and the support.
2. 16-INCH TYPE
Refer to 15-inch type. <Ref. to BR-19, 15-INCH
TYPE, REMOVAL, Front Disc Rotor.>
3. 17-INCH TYPE
Refer to 15-inch type. <Ref. to BR-19, 15-INCH
TYPE, REMOVAL, Front Disc Rotor.>
B: INSTALLATION
1) Install the disc rotor.
2) Install the caliper body and the support to hous-
ing.
Tightening torque:
80 N
⋅ m (8.2 kgf-m, 59 ft-lb)
3) Install the front wheels.
C: INSPECTION
1) Check front wheel bearing play and axial hub
runout before disc rotor runout limit inspection.
<Ref. to DS-15, INSPECTION, Front Axle.>
2) Secure the disc rotor by tightening five wheel
nuts.
3) Set a dial gauge 10 mm (0.39 in) inward of rotor
outer perimeter. Turn the discrotor to checkrunout.
If the disc rotor runout exceeds specified value, re-
place with a new disc rotor.
Disc rotor runout limit:
0.05 mm (0.0020 in)
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 with a new disc rotor.
BR-0001
7
B
A
BR-0001
8
Standard
value Limit Disc rotor
outer diam-
eter
Disc rotor
thickness A
mm (in)
15″24 (0.94) 22 (0.87) 277
(10.91)
16″24 (0.94) 22 (0.87) 294
(11.57)
17″30 (1.18) 28 (1.10) 316
(12.44)
BR-00019
B
A
BR-0001
8