Subaru Legacy (2005 year). Manual - part 32

PM-35

PERIODIC MAINTENANCE SERVICES

Disc Brake Pad and Disc

18.Disc Brake Pad and Disc

A: INSPECTION

1) Jack-up the vehicle and support with rigid racks.
Then remove the wheels.
2) Visually check the pad thickness through inspec-
tion hole of disc brake assembly. Replace the pad if
necessary.

NOTE:
When replacing a pad, always replace the pads for
both the left and right wheels at the same time. Also
replace the pad clips if they are twisted or worn.

• Front

• Rear

3) Check the disc rotor, and correct or replace if it is
damaged or worn.
• Front

• Rear

4) Remove the caliper body. <Ref. to BR-20, Front
Disc Brake Assembly.> <Ref. to BR-28, Rear Disc
Brake Assembly.>
5) Tighten the wheel nuts to secure disk rotor.
6) Set a dial gauge at a point less than 10 mm (0.39
in) from outer periphery of the rotor, and then mea-
sure the disk rotor runout.

Disc rotor runout limit:

Front: 0.05 mm (0.002 in)
Rear: 0.05 mm (0.002 in)

(A) Inspection hole

Pad thickness

mm (in)

Standard

15-inch

11 (0.43)

16-inch

11 (0.43)

17-inch

11 (0.43)

Wear limit

15-inch

1.5 (0.059)

16-inch

1.5 (0.059)

17-inch

1.5 (0.059)

Pad thickness

mm (in)

Standard

Solid disc type

9 (0.35)

Ventilated disc type

9 (0.35)

Wear limit

Solid disc type

1.5 (0.059)

Ventilated disc type

1.5 (0.059)

PM-00049

(A)

(A) Pad thickness

(B) Back metal

(C) Lining

Disc rotor thickness

mm (in)

Standard

15, 16-inch

24 (0.94)

17-inch

30 (1.18)

Wear limit

15, 16-inch

22 (0.87)

17-inch

28 (1.10)

Disc rotor thickness

mm (in)

Standard

Solid disc type

10 (0.39)

Ventilated disc type

18 (0.71)

Wear limit

Solid disc type

8.5 (0.34)

Ventilated disc type

16 (0.63)

PM-00140

(A)

(C)

(B)

PM-00051

PM-36

PERIODIC MAINTENANCE SERVICES

Parking Brake

19.Parking Brake

A: INSPECTION

Inspect the brake linings and disc rotor of both
sides of the rear brake at the same time by remov-
ing disc rotor.
1) Inspect the brake shoes for damage or deforma-
tion and check the brake linings for wear.

NOTE:
Always replace both primary and secondary brake
shoes for the left and right wheels at the same time.

Thickness of brake lining (except for back met-
al):

Standard: 3.2 mm (0.126 in)
Wear limit: 1.5 mm (0.059 in)

2) Check the inside of disk rotor for wear, dents or
other damage. If the inside surface of dick rotor is
streaked, correct the surface with emery cloth
(#200 or more). If it is unevenly worn or tapered,
correct or replace it.

Brake drum inside diameter:

Standard: 170 mm (6.69 in)
Wear limit: 171 mm (6.73 in)

3) If the deformation or wear of back plate, shoe,
etc. is noticeable, replace them.

4) When the shoe return spring tension is exces-
sively weakened, replace it.

B: ADJUSTMENT

For rear disc brake, adjust the parking brake after
bleeding air.
1) Remove the rear cover (rubber) installed at back
plate.
2) Turn the adjuster toward arrow mark (upward)
until it is locked slightly, by using flat-tip screwdriver
as shown in the illustration.

3) Turn back (downward) the adjuster 3 to 4 notch-
es.
4) Install the cover (rubber) in original position cor-
rectly.

(A) Forward

(B) Brake shoe (Primary side)

(C) Brake shoe (Secondary side)

(A) Inside diameter

(B) Disc

PM-00054

(B)

(C)

(A)

PM-00055

(A)

(B)

(A) Adjuster

(B) Cover (rubber)

(C) Back plate

PM-00056

(B)

(C)

(A)

PM-37

PERIODIC MAINTENANCE SERVICES

Suspension

20.Suspension

A: INSPECTION

1. SUSPENSION BALL JOINT

1) Jack-up the vehicle until front wheels are off
ground.
2) Grasp the bottom of tire and move it in and out.
If relative movement is observed between the
brake disc cover (A) and end of front arm (D), ball
joint (C) may be excessively worn.

3) Grasp the end of front arm and move it up and
down. Relative movement (A) between the housing
(D) and front arm (C) boss indicates ball joint (B)
may be excessively worn.

4) If relative movement is observed in the step 2),
3), remove and inspect the ball joint. If the free play
exceeds specification, replace the ball joint. <Ref.
to FS-16, Front Ball Joint.>
5) Damage of dust seal
Visually inspect the ball joint dust seal. If it is dam-
aged, remove the front arm. <Ref. to FS-18, Front
Arm.> And measure free play of ball joint. <Ref. to
FS-16, Front Ball Joint.>

(1) When looseness exceeds specification, re-
place the ball joint.
(2) If the dust seal is damaged, replace with a
new ball joint.

NOTE:
When the front arm ball joint has been removed or
replaced, check the toe-in of front wheel. If the front
wheel toe-in is not at specification, adjust the toe-
in. <Ref. to FS-7, Wheel Alignment.>

2. FRONT, REAR SUSPENSION BUSHING

Apply pressure with tire lever etc, and inspect the
bushing for wear or crack. Replace the bushings if
there is wear or crack.

3. WHEEL ARCH HEIGHT

1) Unload the cargoes and set the vehicle in curb
weight (empty) condition.
2) Check the wheel arch height of front and rear
suspensions to ensure that they are within specifi-
cation. <Ref. to FS-7, Wheel Alignment.>
3) When the wheel arch height is out of specifica-
tion, visually inspect following components and re-
place deformed parts.
• Suspension components [Front strut assembly
and rear damper assembly]
• Parts connecting suspension and body
4) If no components are deformed, adjust the
wheel arch height by replacing the suspension
which wheel arch height is out of standard. <Ref. to
FS-7, Wheel Alignment.> <Ref. to RS-8, Wheel
Alignment.>

PM-00057

(A)

(B)

(C)

(D)

PM-00058

(A)

(B)

(C)

(D)

(A) Dust seal

PM-00059

(A)

PM-00180

PM-38

PERIODIC MAINTENANCE SERVICES

Suspension

4. WHEEL ALIGNMENT OF FRONT SUS-
PENSION

1) Check the alignment of front suspension to en-
sure that following items conform to specification.
• Toe-in
• Camber
• Caster
• Steering angle
<Ref. to FS-7, Wheel Alignment.>
2) When the caster angle does not conform to ref-
erence obviously, visually inspect the following
components and replace deformed parts.
• Suspension components [Strut assembly, cross-
member, front arm, etc.]
• Parts connecting suspension and body
3) When the toe-in and camber are out of specifica-
tion, adjust them so that they conform to specifica-
tion.
4) When the right-and-left turning angles of tire are
out of standard, adjust to specification.

5. WHEEL ALIGNMENT OF REAR SUS-
PENSION

1) Check the alignment of rear suspension to en-
sure that following items are within specification.
• Toe-in
• Camber
• Thrust angle
<Ref. to RS-8, Wheel Alignment.>
2) When the camber angle does not conform to
specification, visually inspect the following compo-
nents. If the deformation is observed, replace the
damaged parts.
• Suspension components [Shock absorber, front
link, rear link, upper link, rear arm, sub frame, etc]
• Parts connecting suspension and body
3) When the toe-in and thrust angle are out of spec-
ification, adjust them so that they conform to spec-
ification.

6. OIL LEAKAGE OF STRUT AND SHOCK 
ABSORBER

Visually inspect the front strut and rear shock ab-
sorber for oil leakage. Replace the front strut and
rear shock absorber if oil leaks excessively.

7. TIGHTNESS OF BOLTS AND NUTS

Check the bolts and nuts for looseness. Retighten
the bolts and nuts to specified torque. If the self-
locking nuts and bolts are removed, replace them
with new ones.
• Front suspension
<Ref. to FS-2, General Description.>
• Rear suspension
<Ref. to RS-2, General Description.>

8. DAMAGE TO SUSPENSION PARTS

Check the following parts and the fastening portion
of the vehicle body for deformation or excessive
rusting which impairs the suspension. If necessary,
replace the damaged parts with new ones. If minor
rust formation, pitting, etc. are noted, remove the
rust and take rust prevention measure.
• Front suspension

• Front arm
• Crossmember
• Strut

• Rear suspension

• Sub frame
• Front link
• Rear link
• Upper link
• Rear arm
• Shock absorber

• In the area where salt is sprayed to melt snow on
a road in winter, check suspension parts for dam-
age caused by rust every 12 months after lapse of
60 months. Take rust prevention measure as re-
quired.