Subaru Legacy III (2000-2003 year). Manual - part 824

BR-54

BRAKE

BRAKE PEDAL

2) Check position of pedal pad.

Pedal height: L

AT: 158 mm (6.22 in)
MT: 153 mm (6.02 in)

Brake pedal free play: A

1 — 3 mm (0.04 — 0.12 in) [Depress brake 
pedal pad with a force of less than 10 N (1 
kgf, 2 lb).]

3) If it is not in specified value, adjust it by adjusting
brake booster operating rod length.

(1) Stop light switch

(2) Mat

(3) Toe board

(4) Brake booster operating rod

BR-00106

A

L

( 1 )

( 2 )

( 3 )

( 4 )

BR-55

BRAKE

STOP LIGHT SWITCH

17.Stop Light Switch

A: REMOVAL

1) Disconnect battery ground cable.
2) Disconnect stop light switch connector.
3) Loosen nuts, and unscrew stop light switch to re-
move.

B: INSTALLATION

1) Screw the stop light switch onto a bracket and
secure it temporarily with a nut.
2) Adjust stop light switch position, and then tighten
the nut.
<Ref. to BR-56, ADJUSTMENT, Stop Light
Switch.>

Tightening torque:

8 N·m (0.8 kgf-m, 5.8 ft-lb)

C: INSPECTION

1) If stop light switch does not operate properly (or
if it does not stop at the specified position), replace
with a new one.

Specified position: L

2

+1.5

/

0

 mm (0.079

+0.059

/

0

  in)

2) Measure the clearance between threaded end of
stop light switch and stopper.

CAUTION:
Be careful not to rotate stop light switch.

Stop light switch clearance: A

0.3 mm (0.012 in)

3) If it is not in specified value, adjust it by adjusting
position of stop light switch.

CAUTION:
Be careful not to rotate stop light switch.

(1) Stop light switch

BR-00182

( 1 )

BR-00183

T

(1) Stop light switch

(2) Stopper

(3) Brake pedal

BR-00109

L

BR-00110

A

( 1 )

( 2 )

( 3 )

BR-56

BRAKE

STOP LIGHT SWITCH

D: ADJUSTMENT

Loosen the lock nut, and adjust stop light switch po-
sition until the clearance (A) between threaded end
of the stop light switch and the stopper becomes
0.3 mm (0.012 in). Then, tighten the lock nut. 

(1) Stop light switch

(2) Stopper

(3) Brake pedal

BR-00110

A

( 1 )

( 2 )

( 3 )

BR-57

BRAKE

GENERAL DIAGNOSTICS

18.General Diagnostics

A: INSPECTION

1. BRAKE SYSTEM

Trouble and possible cause

Corrective action

1. Insufficient braking

(1) Fluid leakage from the hydraulic mechanism

Repair or replace (cup, piston seal, piston boot, 
master cylinder piston kit, pipe or hose).

(2) Entry of air into the hydraulic mechanism

Bleed the air.

(3) Excessively wide shoe clearance

Adjust the clearance.

(4) Wear, deteriorated surface material, adhering 
water or fluid on the lining

Replace, grind or clean.

(5) Improper operation of master cylinder, disc cal-
iper, brake booster or check valve

Correct or replace.

2. Unstable or uneven 
braking

(1) Fluid on the lining or rotor

Eliminate cause of fluid leakage, clean, or replace.

(2) Rotor eccentricity

Correct or replace the rotor.

(3) Improper lining contact, deteriorated surface 
material, improper inferior material, or wear

Correct by grinding, or replace.

(4) Deformed back plate

Correct or replace.

(5) Improper tire inflation

Inflate to correct pressure.

(6) Disordered wheel alignment

Adjust alignment.

(7) Loosened back plate or the support installing 
bolts

Retighten.

(8) Loosened wheel bearing

Retighten to normal tightening torque or replace.

(9) Trouble in the hydraulic system

Replace the cylinder, brake pipe or hose.

(10) Uneven effect of the parking brake

Check, adjust, or replace the rear brake and cable 
system.

3. Excessive pedal 
stroke

(1) Entry of air into the hydraulic mechanism

Bleed the air.

(2) Excessive play in the master cylinder push rod

Adjust.

(3) Fluid leakage from the hydraulic mechanism

Repair or replace (cup, piston seal, piston boot, 
master cylinder piston kit, pipe or hose).

4. Brake dragging or 
improper brake return

(1) Insufficient pedal play

Adjust play.

(2) Improper master cylinder return

Clean or replace the cylinder.

(3) Clogged hydraulic system

Replace.

(4) Improper return or adjustment of parking brake

Correct or adjust.

(5) Weakened spring tension or breakage of shoe 
return spring

Replace the spring.

(6) Excessively narrow shoe clearance

Adjust the clearance.

(7) Improper disc caliper operation

Correct or replace.

(8) Improper adjusted wheel bearing

Adjust or replace.

5. Brake noise (1) 
(creak sound)

(1) Hardened or deteriorated lining

Replace the shoe assembly or pad.

(2) Worn lining

Replace the shoe assembly or pad.

(3) Loosened back plate or the support installing 
bolts

Retighten.

(4) Loose wheel bearing

Retighten to normal tightening torque.

(5) Dirty rotor

Clean the rotor, or clean and replace the brake 
assembly.

6. Brake noise (2) 
(hissing sound)

(1) Worn lining

Replace the shoe assembly or pad.

(2) Improper installed shoe or pad

Correct or replace the shoe assembly or pad.

(3) Loose or bent rotor

Retighten or replace.

7. Brake noise (3) 
(click sound)

(1) Excessively worn pad or the support

Replace the pad or the support.

(2) Lack of oil on the shoe ridge surface and 
anchor

Add more grease.