Subaru Legacy (2005 year). Manual - part 827

BR-37

BRAKE

Brake Fluid

10.Brake Fluid

A: INSPECTION

1) Check that the brake fluid level remains between
“MIN” and “MAX”. If out of the specified range, refill
or drain fluid. If the fluid level becomes close to
“MIN”, check the brake pad for wear and refill fluid.
2) Check the fluid for discoloration. If the fluid color
has excessively changed, drain the fluid and refill
with new fluid.

B: REPLACEMENT

CAUTION:
• Keep the brake fluid away from painted sur-
faces of vehicle body. Wash away with water
and wipe off if spilled.
• 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.

NOTE:
• During the operation, keep the brake reservoir
tank filled with brake fluid to eliminate entry of air.
• The brake pedal operating must be very slow.
• For convenience and safety, two people should
do the work.
• The amount of brake fluid required is approxi-
mately 500 m

2 (16.9 US fl oz, 17.6 Imp fl oz) for to-

tal brake system.
1) Either lift-up the vehicle and place rigid racks un-
der it, or lift-up the vehicle and keep it.
2) Remove both the front and rear wheels.
3) Drain brake fluid from the reservoir tank.
4) Refill the reservoir tank with recommended
brake fluid.

Recommended brake fluid:

Refer to the specification of General Descrip-
tion. <Ref. to BR-2, SPECIFICATION, General
Description.>

Perform the same procedure as bleeding operation
of brake line until new brake fluid comes out from
vinyl tube. <Ref. to BR-38, PROCEDURE, Air
Bleeding.>

NOTE:
Perform the brake fluid replacement in the order
from the farthest wheel cylinder from master cylin-
der.

BR-38

BRAKE

Air Bleeding

11.Air Bleeding

A: PROCEDURE

1. MASTER CYLINDER

NOTE:
• If the master cylinder is disassembled or reser-
voir tank is empty, bleed the master cylinder.
• If bleeding of master cylinder is not necessary,
bleed the brake line by skipping the procedure be-
low. <Ref. to BR-38, BRAKE LINE, PROCEDURE,
Air Bleeding.>
1) Fill the reservoir tank of master cylinder with
brake fluid.

NOTE:
During the operation, keep the reservoir tank filled
with brake fluid to eliminate entry of air.
2) Disconnect the brake line at primary and sec-
ondary sides.
3) Put a plastic bag cover on master cylinder.
4) Slowly depress the brake pedal and hold it.

5) Close the outlet plug with your finger, and then
release the brake pedal.

6) Repeat the step 4) to 5) several times.
7) Remove the plastic bag.

8) Install the brake pipes to master cylinder.

Tightening torque:

Model with ABS

15 N

⋅

m (1.5 kgf-m, 10.8 ft-lb)

Model with VDC

19 N

⋅

m (1.9 kgf-m, 14.0 ft-lb)

9) Bleed air from the brake line. <Ref. to BR-38,
BRAKE LINE, PROCEDURE, Air Bleeding.>

2. BRAKE LINE

1) When the master cylinder has been disassem-
bled or the reservoir tank is empty, bleed the mas-
ter cylinder before bleeding brake line. <Ref. to BR-
38, Air Bleeding.>
2) Fill the reservoir tank of master cylinder with
brake fluid.

NOTE:
During the bleeding operation, keep the reservoir
tank filled with brake fluid to eliminate entry of air.
3) Fit one end of vinyl tube into the air bleeder and
put the other end into a brake fluid container.

4) Depress the brake pedal several times, and hold
it depressed.
5) Loosen the air bleeder screws to discharge
brake fluid. With the air bleeder tightened quickly,
release the brake pedal.
6) Repeat the steps 4) to 5) until there are no more
air bubbles in the vinyl tube.
7) Repeat the steps above from 2) to 6) to bleed air
from each wheel.

NOTE:
Perform the operation in the order from closest
wheel cylinder to master cylinder.
8) Tighten the air bleeder screws securely.

Tightening torque:

8 N

⋅

m (0.8 kgf-m, 5.8 ft-lb)

9) Check that there is no brake fluid leak evident in
the entire system.

BR-00090

BR-00091

BR-00087

BR-39

BRAKE

Air Bleeding

10) Check the pedal stroke.
While the engine is idling after warmed-up, depress
the brake pedal with a 500 N (51 kgf, 112 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.

Specified pedal stroke:

When pressing brake pedal with a force of
500 N (51 kgf, 112 lbf).

Less than 95 mm (3.74 in)

11) If the distance is more than specified, there is a
possibility that air is in the brake line. Bleed the
brake line until pedal stroke meets the specifica-
tion.
12) Operate the hydraulic control unit in the se-
quence control mode. <Ref. to ABS-10, ABS Se-
quence Control.>
13) Recheck the pedal stroke.
14) If the distance is more than specified, there is a
possibility that air is in the hydraulic unit. Repeat
above steps 2) to 9) until pedal stroke meets the
specification.
15) Add brake fluid to the required level (“MAX” lev-
el) of reservoir tank.
16) Test run the vehicle and ensure that brakes
provide normal braking action.

(1) Steering wheel

(2) Toe board

(1)

(2)

BR-00094

BR-40

BRAKE

Brake Hose

12.Brake Hose

A: REMOVAL

1. FRONT BRAKE HOSE

1) Separate the brake pipe from brake hose using a
flare nut wrench.
2) Remove the clamp, bolt at strut mount, and
union bolt.

2. REAR BRAKE HOSE

1) Remove the union bolt from rear brake caliper.

2) Separate the brake pipe from brake hose using a
flare nut wrench.

3) Remove the clamp and remove the brake hose.

B: INSTALLATION

1. FRONT BRAKE HOSE

1) Secure the brake hose to strut mount.

Tightening torque:

33 N

⋅

m (3.4 kgf-m, 24.3 ft-lb)

2) Install the brake hose to caliper using a new gas-
ket.

Tightening torque (Union bolt):

18 N

⋅

m (1.8 kgf-m, 13.0 ft-lb)

(1) Brake hose

(2) Brake pipe

(1) Brake hose

BR-00095

(1)

(2)

BR-00348

(1)

(1) Brake pipe

(2) Brake hose clamp

(1) Brake pipe

(2) Brake hose

(3) Brake hose clamp

(1)

BR-00349

(2)

BR-00350

(1)

(2)

(3)

BR-00021

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