Subaru Legacy III (2000-2003 year). Manual - part 20

PM-30

PERIODIC MAINTENANCE SERVICES

FRONT & REAR DIFFERENTIAL OIL

18.Front & Rear Differential Oil

A: REPLACEMENT

1. FRONT DIFFERENTIAL (MANUAL
TRANSMISSION)

For M/T vehicle, manual transmission oil works as
differential oil to lubricate differential. Refer to
“Transmission Oil”. <Ref. to PM-27, MANUAL
TRANSMISSION, REPLACEMENT, Transmission
Oil.>

2. FRONT DIFFERENTIAL (AUTOMATIC
TRANSMISSION)

1) Drain differential gear oil by removing drain plug
after allowing the engine to cool for 3 to 4 hours.

NOTE:
• Before starting work, cool off the engine well.
• If transmission gear oil splashes on exhaust
pipe, wipe it clean.

2) Reinstall drain plug after draining differential
gear oil and tighten it to the specified torque.

Tightening torque:

44 N·m (4.5 kgf-m, 32.5 ft-lb)

NOTE:
• Be sure to place a gasket between the transmis-
sion case and drain plug.
• Replace the gasket with a new one.
• Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
3) Fill differential gear oil through the oil level
gauge hole up to the upper point of level gauge.

Differential gear oil capacity:

1.1 — 1.3

(1.2 — 1.4 US qt, 1.0 — 1.1 Imp

qt)

PM-00034

(A) Oil level gauge

(B) Upper level

PM-00035

(B)

(C)

(A)

PM-31

PERIODIC MAINTENANCE SERVICES

FRONT & REAR DIFFERENTIAL OIL

3. REAR DIFFERENTIAL

• VA type

1) Drain oil by removing drain plug.
2) Remove filler plug for quicker draining.
3) Replace drain plug gasket with a new one.
4) Tighten drain plug to the specified torque.

Tightening torque:

34 N·m (3.5 kgf-m, 25.3 ft-lb)

5) After installing drain plug, fill oil fully up to the
mouth of filler plug.

Oil capacity:

0.8

(0.8 US qt, 0.7 Imp qt)

6) Replace filler plug gasket with a new one.
7) Install filler plug onto rear differential gear case.

Tightening torque:

34 N·m (3.5 kgf-m, 25.3 ft-lb)

• T type

1) Drain oil by removing drain plug.
2) Remove filler plug for quicker draining.
3) Tighten drain plug after draining oil.

NOTE:
Apply fluid packing to drain plug threads before in-
stallation.

Fluid packing:

Three Bond 1105 (Part No. 004403010)

Tightening torque:

49.0 N·m (5.0 kgf-m, 36.2 ft-lb)

4) After installing drain plug onto rear differential
gear case firmly, fill oil up fully to the mouth of filler
plug.

Oil capacity:

0.8

(0.8 US qt, 0.7 Imp qt)

NOTE:
Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
5) Install filler plug onto rear differential gear case
firmly.

NOTE:
Apply fluid packing to filler plug before installation.

Fluid packing:

Three Bond 1105 (Part No. 004403010)

Tightening torque:

49.0 N·m (5.0 kgf-m, 36.2 ft-lb)

(A) Filler plug

(B) Drain plug

PM-00147

( A )

( B )

(A) Filler plug

(B) Drain plug

PM-00037

(A)

(B)

PM-32

PERIODIC MAINTENANCE SERVICES

BRAKE LINE

19.Brake Line

A: INSPECTION

1. BRAKE LINE

1) Check scratches, swelling, corrosion and/or
traces of fluid leakage on 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 the specified limit, the brake fluid warn-
ing light on the combination meter will come on.
• Visually check brake hose (using a mirror where
it is difficult to see) for any damage.

B: CHECKING

1. SERVICE BRAKE

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

Brake pedal free play:

1 — 3 mm (0.04 — 0.12 in)

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

(1) Be sure 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.
(3) Depress the surface of brake pad by hand.
[Depress brake pedal pad with a force of less
than 10 N (1 kgf, 2 lb) to a stroke of 1 to 3 mm
(0.04 to 0.12 in).]

(A) Front brake pipe

(B) Front brake hose

(A) Rear brake hose

PM-00134

( A )

( B )

PM-00135

( A )

(A) Pedal play

PM-00078

(A)

PM-33

PERIODIC MAINTENANCE SERVICES

BRAKE LINE

(4) 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).

3) Check the pedal stroke.
While the engine is idling, depress the brake pedal
with a 490 N (50 kgf, 110 lb) load and measure the
distance between the brake pedal and steering
wheel. With the brake pedal released, measure the
distance between the pedal and steering wheel
again. The difference between the two measure-
ments must be less than 95 mm (3.74 in). If the dis-
tance is more than specified, there is a possibility
air is in the inside of the hydraulic unit.

Brake pedal reserve distance: A

more than 95 mm (3.74 in)/ 490 N (50 kgf,
110 lb)

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.

2. 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) Check valve is built into vacuum hose. Discon-
nect vacuum hose to inspect function of check
valve.
Blow air into vacuum hose from its brake booster
side end: Air must flow out of engine side end of
hose. Next blow air into hose from engine side: Air
should not flow out of hose.
Replace both check valve and vacuum hose if
check valve is faulty. Engine side of vacuum hose
is indicated by marking “ENG” as shown.

5) Check vacuum hose for cracks or other damage.

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 vacuum hose to make sure it is tight and
secure.

(A) Brake switch

(B) Adjusting nut

(D) Stopper

(E) Clevis pin

(F) Clevis

(G) Pedal play

1 - 3 mm (0.04 - 0.12 in)

(H) Lock nut

(I) Brake booster operating nut

(J) Play at pin

(A) Steering wheel

(B) Toe board

PM-00041

(B)

(G)

(H)

(I)

(J)

(C)

(D)

(E)

(F)

(A)

PM-00045

(B)

(A)

= A

(A) Engine side

(B) Brake booster side

PM-00046

(B)

(C)

(A)

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