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)