Subaru Legacy (2005 year). Manual - part 828

BR-41

BRAKE

Brake Hose

3) Position the disc in straight-forward direction and
route the brake hose through the hole in bracket on
wheel apron side.

CAUTION:
Be sure the brake hose is not twisted.
4) Temporarily tighten the flare nut to connect the
brake pipe and hose.
5) Fix the brake hose with clamp at wheel apron
bracket.
6) Tighten the flare nut to specified torque.

Tightening torque (Brake pipe flare nut):

15 N

⋅

m (1.5 kgf-m, 10.8 ft-lb)

7) Bleed air from brake system.

2. Rear brake hose

1) Pass the brake hose through the hole of bracket,
and lightly tighten the flare nut to connect brake
pipe.
2) Insert the clamp upward to fix brake hose.

3) Install the brake hose to rear brake caliper using
a new gasket.

Tightening torque (Union bolt):

18 N

⋅

m (1.8 kgf-m, 13.0 ft-lb)

4) Tighten the flare nut to specified torque.

Tightening torque (Brake pipe flare nut):

15 N

⋅

m (1.5 kgf-m, 10.8 ft-lb)

5) Bleed air from the brake system.

C: INSPECTION

Ensure there are no cracks, breakage or damage
on hoses. Check joints for fluid leakage. If any
cracks, breakage, damage or fluid leakage is
found, repair or replace the hose.

(1) Brake pipe

(2) Brake hose

(3) Brake hose clamp

(1) Brake pipe

(2) Brake hose clamp

BR-00350

(1)

(2)

(3)

(1)

BR-00349

(2)

(1) Brake hose

BR-00348

(1)

BR-42

BRAKE

Brake Pipe

13.Brake Pipe

A: REMOVAL

NOTE:
Airbag system wiring harness is routed near the
center brake pipe.

CAUTION:
• All airbag system wiring harness and con-
nectors are colored yellow. Do not use the elec-
trical test equipment on these circuits.
• Be careful not to damage the airbag system
wiring harness when servicing the center brake
pipe.
• When removing the brake pipe, make sure
that it is not bent.

B: INSTALLATION

NOTE:
Airbag system wiring harness is routed near the
center brake pipe.

CAUTION:
• All airbag system wiring harness and con-
nectors are colored yellow. Do not use the elec-
trical test equipment on these circuits.
• Be careful not to damage the airbag system
wiring harness when servicing the center brake
pipe.
• When installing the brake pipe, make sure
that it is not bent.
• After installing the brake pipe and hose,
bleed air.
• After installing the brake hose, make sure
that it does not touch the tire or suspension as-
sembly, etc.

Brake pipe tightening torque:

<Ref. to BR-9, FRONT BRAKE PIPES AND 
HOSE, COMPONENT, General Description.>
<Ref. to BR-11, CENTER AND REAR BRAKE 
PIPES AND HOSE, COMPONENT, General 
Description.>

C: INSPECTION

Ensure there are no cracks, breakage or damage
on pipes. Check joints for fluid leakage. If any
cracks, breakage, damage or fluid leakage is
found, repair or replace the pipes.

NOTE:
Use a mirror when inspecting the low-visible part or
backside.

BR-43

BRAKE

Brake Pedal

14.Brake Pedal

A: REMOVAL

1. LHD MT MODEL

1) Remove the steering shaft.
2) Disconnect the connectors (stop light switch)
from pedal bracket.
3) Remove the clevis pin which secures lever to
push rod.
4) Remove the nuts which secure clutch master
cylinder.
5) Remove the bolts and nuts which secure pedal
bracket.

2. LHD AT MODEL

1) Remove the steering shaft.
2) Disconnect the connectors (stop light switch)
from pedal bracket.
3) Remove the clevis pin which secures lever to
push rod.

4) Remove the bolts and nuts which secure pedal
bracket.

3. RHD MODEL

Refer to LHD AT model. <Ref. to BR-43, LHD AT
MODEL, REMOVAL, Brake Pedal.>

B: INSTALLATION

1) Install in the reverse order of removal.

CAUTION:
Always use new clevis pins.
2) Inspect the brake pedal after installation. <Ref.
to BR-44, INSPECTION, Brake Pedal.>

BR-00128

(1) Clevis pin

(2) Snap pin

(3) Operating rod

(2)

(3)

(1)

BR-00351

BR-44

BRAKE

Brake Pedal

C: INSPECTION

1) Move the brake pedal pads in the lateral direc-
tion with a force of approx. 10 N (1 kgf, 2 lbf) to en-
sure pedal deflection is in specified range.

CAUTION:
If excessive deflection is noted, replace the 
bushing with a new one.

Deflection of brake pedal:

Limit

Less than 5.0 mm (0.197 in)

2) Check the position of pedal pad.

Pedal height L:

LHD

150 — 160 mm (5.91 — 6.30 in)

RHD

162 — 172 mm (6.38 — 6.77 in)

Brake pedal free play A:

0.5 — 2 mm (0.02 — 0.08 in) [When pulling the 
brake pedal upward with a force of less than 
10 N (1 kgf, 2 lbf).

3) If it is not within the specification, adjust it by ad-
justing the brake booster operating rod length.

(1) Brake pedal

(1) Stop light switch

(2) Mat

(3) Toe board

(4) Brake booster operating rod

(1)

BR-00105

(1)

(3)

(4)

(2)

A

BR-00106

L