Subaru Legacy (2005 year). Manual - part 31

PM-31

PERIODIC MAINTENANCE SERVICES

Brake Line

16.Brake Line

A: INSPECTION

1. BRAKE LINE

1) Check for scratches, swelling, corrosion, traces
of fluid leakage on the brake hoses or pipe joints.
2) Check the possibility of adjacent parts interfering
with brake pipes/hoses during driving, and loose
connections/clamps.
3) Check any trace of fluid leakage, scratches, etc.
on master cylinder, wheel cylinder and pressure
control valve.

NOTE:
• When the brake fluid level in the reservoir tank is
lower than specified limit, the brake warning light
on the combination meter will come on.
• Visually check the brake hose for damage. (Use
a mirror where it is difficult to see)

2. SERVICE BRAKE

1) Check the free play of brake pedal with pulling
up the force of less than 10 N (1 kgf, 2 lbf).

Brake pedal free play (Pulling up direction of 
pedal)

0.5 — 2.0 mm (0.02 — 0.08 in)

2) If the free play is out of specifications above, ad-
just the brake pedal as follows:

(1) Make sure the engine is off. (No vacuum is
applied to brake booster.)
(2) There should be play between brake boost-
er clevis and pin at brake pedal installing por-
tion. [Pulling up the brake pedal pad with a force
of less than 10 N (1 kgf, 2 lbf) to a stroke of 0.5
to 2.0 mm (0.02 to 0.08 in).]
(3) If there is no free play between clevis pin
and clevis, turn brake switch adjusting nut until
the clearance between stopper and screw of
brake switch becomes 0.3 mm (0.012 in).

(1) Front brake hose

(2) Front brake pipe

(1) Rear brake pipe

(2) Rear brake hose

PM-00171

(2)

(1)

(2)

(1)

PM-00172

(A) Pedal free play

(A) Brake switch

(B) Adjusting nut

(C) 0.3 mm (0.012 in)

(D) Stopper

(E) Clevis pin

(F) Clevis

(G) Pedal free play

(H) Lock nut

(I) Brake booster operating rod

(J) Play at pin

PM-00185

(A)

PM-00186

(B)

(G)

(H)

(I)

(J)

(C)

(D)

(E)

(F)

(A)

PM-32

PERIODIC MAINTENANCE SERVICES

Brake Line

3) Check the pedal stroke.
While the engine is idling, depress the brake pedal
with a 490 N (50 kgf, 110 lbf) load and measure the
distance between the brake pedal and steering
wheel. With the brake pedal released, measure the
distance between pedal and steering wheel again.
The difference between the two measurements
must be less than specification. If the distance is
more than specification, there is possibility of air in-
side the hydraulic unit.

Brake pedal stroke A:

95 mm (3.7 in)/ 490 N (50 kgf, 110 lbf) or less

4) Check to see if air is in the hydraulic brake line
by the feel of pedal operation. If air appears to exist
in the line, bleed it from the system.
5) Check for even operation of all brakes, using a
brake tester or by driving the vehicle for a short dis-
tance on a straight road.

3. BRAKE SERVO SYSTEM

1) With the engine off, depress the brake pedal
several times applying the same pedal force. Make
sure the travel distance should not change.
2) With the brake pedal depressed, start the en-
gine. Make sure the pedal should move slightly to-
ward the floor.
3) With the brake pedal depressed, stop the engine
and keep the pedal depressed for 30 seconds.
Make sure the pedal height should not change.
4) A check valve is built into the vacuum hose. Dis-
connect the vacuum hose to inspect function of
check valve.
Blow compressed air into vacuum hose from its
brake booster side end. Make sure air must flow
out of engine side end of hose. Next, blow com-
pressed air into hose from engine side. Make sure
air should not flow out of hose.

Replace the both check valve and vacuum hose if
the check valve is faulty. Engine side of vacuum
hose is indicated by marking “ENG” as shown.

5) Check the vacuum hose for cracks or other dam-
age.

NOTE:
When installing the vacuum hose on the engine
and brake booster, do not use soapy water or lubri-
cating oil on their connections.
6) Check the vacuum hose to make sure it is tightly
secured.

(A) Steering wheel

(B) Toe board

PM-00045

(B)

(A)

= A

1

1

2

2

(A) Engine side

(B) Brake booster side

(C) ENG

PM-00046

(B)

(C)

(A)

PM-33

PERIODIC MAINTENANCE SERVICES

Brake Fluid

17.Brake Fluid

A: REPLACEMENT

CAUTION:
Be careful not to let the brake fluid get on the 
vehicle body. If the brake fluid gets on the vehi-
cle body, flush it quickly, and then wipe it off.
1) Either jack-up the vehicle and place a rigid rack
under it, or lift-up the vehicle.
2) Remove all the wheels.
3) Drain the brake fluid from master cylinder.
4) Refill the reservoir tank with recommended
brake fluid.

Recommended brake fluid:

Refer to “RM” section. <Ref. to RM-5, FLUID, 
RECOMMENDED MATERIALS, Recommend-
ed Materials.>

NOTE:
• Avoid mixing different brands of brake fluid to
prevent degrading the quality of fluid.
• Be careful not to allow dirt or dust to get into the
reservoir tank.
Air bleeding sequence (1) 

→ (2) → (3) → (4)

5) Install one end of a vinyl tube onto the air bleeder
and insert the other end of the tube into a container
to collect the brake fluid.

NOTE:
• Cover the bleeder with cloth, when loosening it,
to prevent brake fluid from being splashed over sur-
rounding parts.
• During the bleeding operation, keep the brake
reservoir tank filled with brake fluid to eliminate en-
try of air.
• The brake pedal operation must be very slow.
• For convenience and safety, two people should
do the work.
• The amount of brake fluid required is approx. 500
m

2 (16.9 US fl oz, 17.6 Imp fl oz) for total brake

system.
6) Instruct your co-worker to depress the brake
pedal slowly two or three times and then hold it de-
pressed.
7) Loosen the bleeder screw approximately 1/4
turn until a small amount of brake fluid drains into
the container, and then quickly tighten the screw.
8) Repeat steps 6) and 7) until there are no air bub-
bles in drained brake fluid and new fluid flows
through vinyl tube.

NOTE:
Add brake fluid as necessary while performing the
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold the
brake pedal depressed and tighten the screw and
install bleeder cap.

Tightening torque:

8 N

⋅

m (0.8 kgf-m, 5.9 ft-lb)

10) Bleed air from each wheel cylinder by following
steps from 5) to 9).
11) Depress the brake pedal with a force of approx.
294 N (30 kgf, 66 lbf) and hold it there for approx.
20 seconds. At this time check the pedal to see if it
makes any unusual movement. Visually inspect the
bleeder screws and brake pipe joints to confirm
there is no fluid leakage.

(1) Front RH

(2) Rear LH

(3) Front LH

(4) Rear RH

(5) Secondary

(6) Primary

(1)

(4)

(2)

(3)

(5)

(6)

PM-00047

PM-00048

PM-34

PERIODIC MAINTENANCE SERVICES

Brake Fluid

12) Install the wheels, and drive the vehicle for a
short distance between 2 to 3 km (1 to 2 miles) to
confirm brakes are operating properly.