Subaru Legacy III (2000-2003 year). Manual - part 823

BR-50

BRAKE

BRAKE PEDAL

16.Brake Pedal

A: REMOVAL

1. MT MODEL

• LHD model

1) Pull up parking brake lever and block tires.
2) Disconnect battery ground cable.
3) Remove steering column.
<Ref. to PS-28, REMOVAL, Tilt Steering Column.>
4) Disconnect connectors from stop light and clutch
switches.
5) Remove snap pins which secure lever to push
rod and operating rod.
6) Remove clevis pins which secure lever to push
rod and operating rod.

7) Remove PHV adjusting nut and lock nut.

8) Remove cable clamp, and disconnect PHV ca-
ble from PHV.

CAUTION:
Carefully protect boot and inner cable from 
damage when disconnecting PHV cable.

9) Remove nut which secures clutch master cylin-
der.

10) Remove bolts and nuts which secure brake and
clutch pedals, and remove pedal assembly.

(A) Operating rod

(B) Push rod

(C) Snap pin

(D) Clevis pin

(1) Adjusting nut

(2) Lock nut

(3) PHV

BR-00174

( B )

( C )

( D )

( D )

( C )

( A )

BR-00131

( 1 )

( 2 )

( 3 )

(1) PHV cable

(2) Clamp

BR-00132

( 1 )

( 2 )

BR-00175

BR-51

BRAKE

BRAKE PEDAL

• RHD model

1) Pull up parking brake lever and block tires.
2) Disconnect ground cable from battery.
3) Remove instrument panel lower cover from in-
strument panel.
4) Remove clevis pin which secures brake pedal to
brake booster operating rod. Also disconnect elec-
trical connectors (for stop light switch, etc.).

5) Remove nuts and bolts which secure pedal
bracket.

2. AT MODEL

• LHD model

1) Pull up parking brake lever.
2) Disconnect ground cable from battery.
3) Remove instrument panel lower cover from in-
strument panel.
4) Remove clevis pin which secures brake pedal to
brake booster operating rod. Also disconnect stop
light switch connector.
5) Remove AT unit from brake panel (2 nuts).
6) Remove two bolts and four nuts which secure
brake pedal to pedal.

• RHD model

NOTE:
For removal procedures, refer to “MT MODEL”.
<Ref. to BR-50, MT MODEL, REMOVAL, Brake
Pedal.>

B: INSTALLATION

1) Install in the reverse order of removal.

CAUTION:
• If cable clamp is damaged, replace it with a
new one.
• Never fail to cover outer cable end with boot.
• Be careful not to kink accelerator cable.
• Always use new clevis pins.
2) Adjustment of clutch pedal <Ref. to BR-53, AS-
SEMBLY, Brake Pedal.>
3) Inspect after pedal installation <Ref. to BR-53,
INSPECTION, Brake Pedal.>

(A) Snap pin

(B) Clevis pin

(A) Brake pedal bracket

BR-00225

( A )

( B )

( A )

BR-00226

BR-00176

BR-52

BRAKE

BRAKE PEDAL

C: DISASSEMBLY

1. MT MODEL

• LHD model

1) Remove the brake switch.
<Ref. to BR-55, REMOVAL, Stop Light Switch.>
2) Remove the clutch pedal.
<Ref. to CL-34, DISASSEMBLY, Clutch Pedal.>
3) Remove the clutch master cylinder bracket.

4) Remove bushing, spring and stopper.

5) Remove the brake pedal pad.
• RHD model

NOTE:
For disassembly procedures, refer to “AT MODEL”.
<Ref. to BR-52, AT MODEL, DISASSEMBLY,
Brake Pedal.>

2. AT MODEL

1) Remove the brake switch.
2) Unbolt, and then remove the brake pedal.

3) Remove bushing, spacer and spring.

4) Remove the brake pedal pad.

(1) Stopper

(2) Bushing

(3) Brake pedal

(4) Brake pedal spring

BR-00177

BR-00178

( 3 )

( 4 )

( 2 )

( 1 )

( 2 )

(1) Spacer

(2) Bushing

(3) Stopper

(4) Brake pedal

(5) Brake pedal spring

BR-00179

BR-00180

( 1 )

( 2 )

( 2 )

( 3 )

( 4 )

( 5 )

BR-53

BRAKE

BRAKE PEDAL

D: ASSEMBLY

1) Attach stop light switch, etc. to pedal bracket
temporarily.
2) Clean inside of bores of clutch pedal and brake
pedal, apply grease, and set bushings into bores.
3) Align bores of pedal bracket, clutch pedal and
brake pedal, attach brake pedal return spring and
clutch pedal effort reducing spring (vehicle with hill
holder), and then install pedal bolt.

NOTE:
Clean up inside of bushings and apply grease be-
fore installing spacer.

Tightening torque:

T: 29 N·m (3.0 kgf-m, 21.7 ft-lb)

4) Set brake pedal position by adjusting position of
stop light switch.

Pedal position: L

LHD: 126.4 mm (4.98 in)
RHD: 154.9 mm (6.10 in)

Tightening torque:

T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)

E: INSPECTION

1) Move brake and clutch pedal pads in the lateral
direction with a force of approximately 10 N (1 kgf,
2 lb) to ensure pedal deflection is in specified
range.

CAUTION:
If excessive deflection is noted, replace bush-
ings with new ones.

Deflection of brake and clutch pedal:

Service limit

5.0 mm (0.197 in) or less

BR-00102

T

BR-00181

L

T

(1) Clutch pedal

(2) Brake pedal

(1) Brake pedal

( 1 )

( 2 )

BR-00104

BR-00105

( 1 )