Subaru 2004 LEGACY Bedienungsanleitung

FUJI HEAVY INDUSTRIES LTD. G2320GE6

2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

CHASSIS SECTION

This service manual has been prepared

to provide SUBARU service personnel

with the necessary information and data

for the correct maintenance and repair

of SUBARU vehicles.

This manual includes the procedures

for maintenance, disassembling, reas-

sembling, inspection and adjustment of

components and diagnostics for guid-

ance of experienced mechanics.

Please peruse and utilize this manual

fully to ensure complete repair work for

satisfying our customers by keeping

their vehicle in optimum condition.

When replacement of parts during

repair work is needed, be sure to use

SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are

based on the latest product information

available at the time of publication

approval.

FRONT SUSPENSION FS

REAR SUSPENSION RS

WHEEL AND TIRE SYSTEM WT

DIFFERENTIALS DI

TRANSFER CASE TC

DRIVE SHAFT SYSTEM DS

ABS ABS

ABS (DIAGNOSTICS) ABS(diag)

VEHICLE DYNAMICS CONTROL (VDC) VDC

VEHICLE DYNAMICS CONTROL (VDC)

(DIAGNOSTICS) VDC(diag)

BRAKE BR

PARKING BRAKE PB

POWER ASSISTED SYSTEM

(POWER STEERING) PS

PARKING BRAKE PB

Page

1. General Description ....................................................................................2

2. Parking Brake Lever....................................................................................5

3. Parking Brake Cable...................................................................................6

4. Parking Brake Assembly (Rear Disc Brake) ...............................................7

5. General Diagnostic Table..........................................................................10

PB-2

PARKING BRAKE General Description

1. General Description

A: SPECIFICATION

Type Mechanical on rear brakes, drum in disc

Effective drum

diameter mm (in) 170 (6.69)

Lining dimensions

(length ×width ×

thickness) mm (in) 163.1 ×30.0 ×3.2

(6.421 ×1.181 ×0.126)

Clearance adjustment Manual adjustment

Lever stroke notches/N (kgf, lb) 5 to 6/200 (20.4, 45)

PB-3

PARKING BRAKE

General Description

B: COMPONENT

1. PARKING BRAKE (REAR DISC BRAKE)

(1) Back plate (7) Strut spring (13) Adjuster

(2) Retainer (8) Strut (14) Shoe hold-down cup

(3) Spring washer (9) Shoe guide plate (15) Shoe hold-down spring

(4) Lever (10) Primary return spring (16) Shoe hold-down pin

(5) Parking brake shoe (Primary) (11) Secondary return spring (17) Adjusting hole cover

(6) Parking brake shoe (Secondary) (12) Adjusting spring

PB-00048

(16)

(10)

(13)

(11)

(9)

(6)

(2)

(1)

(17)

(3)

(4)

(7)

(8)

(14)

(15)

(12)

(5)

PB-4

PARKING BRAKE General Description

2. PARKING BRAKE CABLE

C: CAUTION

• Wear work clothing, including a cap, protective

goggles, and protective shoes during operation.

• Before removal, installation or disassembly, be

sure to clarify the failure. Avoid unnecessary re-

moval, installation, disassembly and replacement.

• Be careful not to burn your hands, because each

part on the vehicle is hot after running.

• Use SUBARU genuine grease etc. or the equiv-

alent. Do not mix grease etc. with that of another

grade or from other manufacturers.

• Be sure to tighten fasteners including bolts and

nuts to the specified torque.

• Place shop jacks or rigid racks at the specified

points.

• Before securing a part on a vice, place cushion-

ing material such as wood blocks, aluminum plate,

or shop cloth between the part and the vice.

• Keep grease etc. away from parking brake

shoes.

(1) Parking brake lever (6) Clamp Tightening torque: N

⋅

m (kgf-m, ft-lb)

(2) Parking brake switch (7) Parking brake cable RH T1: 18 (1.8, 13.0)

(3) Adjusting nut (Self-locking nut) (8) Clamp T2: 33 (3.4, 24.3)

(4) Equalizer (9) Parking brake cable LH

(5) Bracket

PB-00056

(5)

(6)

(7)

(8)

(9)

(8)

(1) (3)

(2) (4)

PB-5

PARKING BRAKE

Parking Brake Lever

2. Parking Brake Lever

A: REMOVAL

1) Set the wheel stoppers to tires.

2) Remove the console box.

3) Disconnect the parking brake switch connector.

4) Remove the parking cable adjusting nut (self-

locking nut).

5) Remove the parking brake lever.

B: INSTALLATION

1) Install in the reverse order of removal.

Tightening torque:

Parking brake lever

18 N

⋅

m (1.8 kgf-m, 13.0 ft-lb)

2) Install a new adjusting nut (self-locking nut).

3) Adjust the lever stroke. <Ref. to PB-5, ADJUST-

MENT, Parking Brake Lever.>

C: INSPECTION

1) Operate the parking brake lever 3 to 4 times and

return the lever fully.

2) While pulling the parking brake lever upward,

count the notches.

Lever stroke:

5 to6 notcheswhen pulled with a forceof 200

N (20.4 kgf, 45 lb)

If it is not within the specified value, adjust the park-

ing brake. <Ref. to PB-9, ADJUSTMENT, Parking

Brake Assembly (Rear Disc Brake).>

D: ADJUSTMENT

Adjust the parking lever stroke. <Ref. to PB-9, LE-

VER STROKE, ADJUSTMENT, Parking Brake As-

sembly (Rear Disc Brake).>

PB-00053

PB-6

PARKING BRAKE Parking Brake Cable

3. Parking Brake Cable

A: REMOVAL

1) Remove the rear seat cushion.

2) Remove the console box.

3) Remove the parking cable adjusting nut (self-

locking nut).

4) Remove the parking brake lever. <Ref. to PB-5,

REMOVAL, Parking Brake Lever.>

5) Roll up the floor mat and remove the clamps.

6) Remove the inner cable end from equalizer.

7) Lift-up the vehicle, and then remove the rear

wheels.

8) Remove the parking brake cable from rear

brake. <Ref. to PB-7, REMOVAL, Parking Brake

Assembly (Rear Disc Brake).>

9) Remove the clamp from rear brake.

10) Remove the cable clamp from rear arm brack-

et.

11) Remove the cable clamp from rear floor.

12) Remove the cable assembly.

B: INSTALLATION

1) Install in the reverse order of removal.

NOTE:

Be sure to pass the cable through the cable guide

inside tunnel.

2) Adjust the lever stroke. <Ref. to PB-5, ADJUST-

MENT, Parking Brake Lever.>

C: INSPECTION

Check and replace the removed cable if damaged,

rusty or faulty.

1) Check the cable for smooth operation.

2) Check the inner cable for damage and rust.

3) Check the outer cable for damage, bends and

cracks.

4) Check the boot for damage, cracks and corro-

sion.

(1) Equalizer

(2) Inner cable end

PB-00043

PB-0000

PB-00026

PB-7

PARKING BRAKE

Parking Brake Assembly (Rear Disc Brake)

4. Parking Brake Assembly

(Rear Disc Brake)

A: REMOVAL

1) Release the parking brake.

2) Remove the two mounting bolts and remove the

brake caliper assembly.

3) Suspend the brake caliper assembly so that the

hose is not stretched.

4) Remove the disc rotor.

NOTE:

If the disc rotor is difficult to remove, try the follow-

ing two methods in order.

(1) Turn the adjusting screw using a flat tip

screwdriver until the brake shoe gets away

enough from the disc rotor.

(2) If the disc rotor seizes up within hub, drive

out the disc rotor by pushing two 8 mm bolts in

holes B on rotor.

5) Remove the shoe return spring from parking

brake assembly.

6) Remove the front shoe hold down spring and

pin.

7) Remove the strut and strut spring.

8) Remove the adjuster assembly from parking

brake assembly.

9) Remove the brake shoe.

10) Remove the rear shoe hold down spring and

pin with pliers.

11) Remove the parking brake cable from lever.

12) Using a flat tip screwdriver, raise the retainer.

Remove the parking lever and washer from brake

shoe.

(1) Adjuster

(2) Adjusting hole cover (rubber)

(3) Flat tip screwdriver

(4) Back plate

BR-00346

(1)

(4)

(2)

(3)

BR-0015

(1) Parking brake cable

(2) Lever

BR-0003

PB-00028

PB-0001

PB-8

PARKING BRAKE Parking Brake Assembly (Rear Disc Brake)

B: INSTALLATION

CAUTION:

Be sure the lining surface is free from oil and

grease contamination.

1) Apply brake grease to the following places.

Brake grease:

Brake Grease (Part No. 003602002)

• Six contact surfaces of shoe rim and back plate

packing

• Contact surface of shoe wave and anchor pin

• Contact surface of lever and strut

• Contact surface of shoe wave and adjuster as-

sembly

• Contact surface of shoe wave and strut

• Contact surface of lever and shoe wave

2) Insert the primary side brake shoe into anchor

pin groove.

3) Secure the brake shoe with the shoe hold-down

pin and cup.

4) Install the plate to anchor pin, and then assem-

ble the primary return spring to anchor pin.

5) Install the parking brake cable to parking brake

lever.

6) Assemble the strut and adjuster, and then se-

cure the secondary side brake shoe with shoe hold-

down pin and cup.

NOTE:

• Install the strut spring of both right and left wheel

facing vehicle front.

• Install the adjuster assembly with screw on left

side.

7) Install the secondary return spring and adjusting

spring.

8) Adjust the parking brake. <Ref. to PB-9, AD-

JUSTMENT, Parking Brake Assembly (Rear Disc

Brake).>

9) Drive the vehicle for parking brake lining “break-

in”.(1) Drive the vehicle at about 35 km/h (22

MPH).

(2) With the parking brake release button

pushed in, pull the parking brake lever gently.

(3) Drive the vehicle for about 200m (0.12 mile)

in this condition.

(4) Wait 5 to 10 minutes for the parking brake to

cool down.

Repeat once more from step (1).

(5) After breaking-in, re-adjust the parking

brakes.

(1) Primary return spring

(2) Anchor pin

(3) Plate

(4) Primary shoe

(5) Shoe hold-down pin and shoe hold-down cup

PB-0003

(1)

(4)

(5)

(2)

(3)

(1) LH

(1) Lever

(2) Secondary brake shoe

(3) Strut spring

(4) Strut

(5) Return spring

(6) Adjuster

(7) Shoe hold-down cup

(8) Adjusting spring

PB-0001

(1) (2)

(4)

(3)

(5)

(7)

(8) (6)

PB-9

PARKING BRAKE

Parking Brake Assembly (Rear Disc Brake)

C: INSPECTION

1) Measure the brake disc rotor inside diameter. If

the disc is scored or worn, replace the brake disc

rotor.

Disc rotor inside diameter:

Standard:

170 mm (6.69 in)

Service limit:

171 mm (6.73 in)

2) Measure the lining thickness. If it exceeds the

limit, replace shoe assembly.

Lining thickness:

Standard:

3.2 mm (0.126 in)

Service limit:

1.5 mm (0.059 in)

NOTE:

Replace the right and left brake shoe as a set.

D: ADJUSTMENT

1. SHOE CLEARANCE

1) Return the parking brake lever fully.

2) Remove the adjusting hole cover from back

plate.

3) Turn the adjusting screw using a flat tip screw-

driver until the brake shoe is in close contact with

disc rotor.

4) Turn back (downward) the adjusting screw 3 to 4

notches.

CAUTION:

Check there is no brake drag.

5) Install the adjusting hole cover to back plate.

6) Adjust the parking lever stroke. <Ref. to PB-9,

LEVER STROKE, ADJUSTMENT, Parking Brake

Assembly (Rear Disc Brake).>

2. LEVER STROKE

1) Adjust the shoe clearance before lever stroke

adjustment. <Ref. to PB-9, SHOE CLEARANCE,

ADJUSTMENT, Parking Brake Assembly (Rear

Disc Brake).>

2) Remove the parking lever cover.

3) Operate the parking brake lever 3 to 4 times.

4) Turn the adjusting nut until lever stroke is at the

specification.

Lever stroke:

5 to 6 notches when pulled witha forceof 200

N (20.4 kgf, 45 lb)

5) Check there is no brake drag.

6) Install the parking lever cover.

(1) Adjusting screw

(2) Adjusting hole cover (rubber)

(3) Flat tip screwdriver

(4) Back plate

(1)

(4)

(2)

(3)

PB-0003

(1) Adjusting nut (Self-locking nut)

PB-00054

(1)

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