Subaru Legacy III (2000-2003 year). Manual - part 21

 

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Subaru Legacy III (2000-2003 year). Manual - part 21

 

 

PM-34

PERIODIC MAINTENANCE SERVICES

BRAKE FLUID

20.Brake Fluid

A: REPLACEMENT

1) Either jack up vehicle and place a safety stand
under it, or lift up vehicle. 
2) Remove both front and rear wheels.
3) Draw out the brake fluid from master cylinder
with syringe.
4) Refill reservoir tank with recommended brake
fluid.

Recommended brake fluid:

FMVSS No. 116, fresh DOT3 or 4 brake fluid

NOTE:
• Avoid mixing different brands of brake fluid to
prevent degrading the quality of the fluid.
• Be careful not to allow dirt or dust to get into the
reservoir tank.
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 bleeder with waste cloth, when loosening
it, to prevent brake fluid from being splashed over
surrounding parts.
• During bleeding operation, keep the brake re-
serve tank filled with brake fluid to eliminate entry of
air.
• Brake pedal operation must be very slow.
• For convenience and safety, it is advisable to
have two men working.
• 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.
6) Instruct your co-worker to depress the brake
pedal slowly two or three times and then hold it de-
pressed.
7) Loosen bleeder screw approximately 1/4 turn
until a small amount of brake fluid drains into con-
tainer, and then quickly tighten screw.
8) Repeat steps 6) and 7) above until there are no
air bubbles 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
brake pedal depressed and tighten screw and in-
stall bleeder cap.

Tightening torque:

8 N·m (0.8 kgf-m, 5.8 ft-lb)

10) Bleed air from each wheel cylinder by following
the previous 5 steps.
11) Depress brake pedal with a force of approxi-
mately 294 N (30 kgf, 66 lb) and hold it there for ap-
proximately 20 seconds. At this time check pedal to
see if it makes any unusual movement. Visually in-
spect bleeder screws and brake pipe joints to make
sure that there is no fluid leakage.
12) Install wheels, and drive vehicle for a short dis-
tance between 2 to 3 km (1 to 2 miles) to make sure
that brakes are operating properly.

(1) Front right

(2) Rear left

(3) Front left

(4) Rear right

(5) Secondary

(6) Primary

PM-00047

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

PM-00048

PM-35

PERIODIC MAINTENANCE SERVICES

DISC BRAKE PADS AND DISCS

21.Disc Brake Pads and Discs

A: INSPECTION

1. DISC BRAKE PAD AND DISC

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

3) Check the disc rotor, and correct or replace if it is
damaged or worn.
• Non-turbo model

• Turbo model

4) Measure the disc rotor runout at a point less than
10 mm (0.39 in) from the outer periphery of the ro-
tor.

Disc rotor runout limit:

Front: 0.075 mm (0.0030 in)
Rear: 0.070 mm (0.0028 in)

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

(A) Inspection hole

Pad thickness mm (in)

Front

Rear

Standard

11 (0.43)

9 (0.35)

Service limit

1.5 (0.059)

1.5 (0.059)

(A) Thickness of pad

(B) Back metal

(C) Lining

Brake disc thickness mm (in)

Front

Rear

Standard

24 (0.94)

10 (0.39)

Wear limit

22 (0.87)

8.5 (0.335)

PM-00049

(A)

PM-00140

(A)

(C)

(B)

Brake disc thickness mm (in)

Front

Rear

Standard

24 (0.94)

18 (0.71)

Wear limit

22 (0.87)

16 (0.63)

PM-00051

PM-36

PERIODIC MAINTENANCE SERVICES

PARKING BRAKE

22. Parking Brake 

A: INSPECTION

Inspect brake linings and drums of both sides of the
rear brake at the same time by removing brake
drums.
1) Inspect brake shoes for damage or deformation
and check brake linings for wear.

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

Brake lining thickness excluding back metal

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

2) Check brake drum for wear, dents or other dam-
age. If the inside surface of brake drum is streaked,
correct the surface with emery cloth (#200 or
more). If it is unevenly worn, tapered, or the outside
surface of brake drum is damaged, correct or re-
place it.

Brake drum inside diameter

Standard value: 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, taking care to identify
upper and lower springs.

(A) Front

(B) Brake shoe (Primary)

(C) Brake shoe (Secondary)

(A) Measuring inside diameter

(B) Disc

PM-00054

(B)

(C)

(A)

PM-00055

(A)

(B)

PM-37

PERIODIC MAINTENANCE SERVICES

PARKING BRAKE

B: ADJUSTMENT

1. SHOE CLEARANCE

1) Remove adjusting hole cover from back plate.
2) Turn adjusting screw using a slot-type screw-
driver until brake shoe is in close contact with disc
rotor.

3) Turn back (downward) adjusting screw 3 or 4
notches.
4) Install adjusting hole cover to back plate.

2. LEVER STROKE

1) Remove console box lid.
2) Forcibly pull parking brake lever 3 to 5 times.
3) Adjust parking brake lever by turning adjuster
until parking brake lever stroke is set at 6 notches
with operating force of 196 N (20 kgf, 44 lb).

4) Tighten lock nut.
5) Install console box lid.

Lever stroke:

7 to 8 notches when pulled with a force of 
196 N (20 kgf, 44 lb)

Tightening torque (Adjuster lock nut):

5.9 N·m (0.60 kgf-m, 4.3 ft-lb)

(A) Adjusting screw

(B) Cover (rubber)

(C) Back plate

(A) Parking brake lever

(B) Lock nut

(C) Adjusting nut

PM-00056

(B)

(C)

(A)

PM-00136

( A )

( B )

( C )

 

 

 

 

 

 

 

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