Subaru LEGACY 2004 Service Manual
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Subaru LEGACY 2004 Service Manual

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2004 LEGACY SERVICE MANUAL
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.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FRONT SUSPENSION
REAR SUSPENSION
WHEEL AND TIRE SYSTEM
DIFFERENTIALS
TRANSFER CASE
DRIVE SHAFT SYSTEM
ABS
ABS (DIAGNOSTICS)
VEHICLE DYNAMICS CONTROL (VDC)
VEHICLE DYNAMICS CONTROL (VDC)
(DIAGNOSTICS)
BRAKE
PARKING BRAKE
POWER ASSISTED SYSTEM
(POWER STEERING)
FS
RS
WT
DI
TC
DS
ABS
ABS(diag)
VDC
VDC(diag)
BR
PB
PS
G2320GE6

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Summary of Contents for Subaru LEGACY 2004

  • Page 1 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...

  • Page 2: Table Of Contents

    BRAKE Page General Description ..................2 Front Brake Pad ..................16 Front Disc Rotor ..................19 Front Disc Brake Assembly...............20 Rear Brake Pad..................25 Rear Disc Rotor..................26 Rear Disc Brake Assembly ...............28 Master Cylinder ..................30 Brake Booster ...................32 Brake Fluid ....................36 Air Bleeding....................38 Brake Hose ....................40 Brake Pipe....................42 Brake Pedal....................43 Stop Light Switch ..................45...

  • Page 3: General Description

    • When brake fluid is supplemented, be careful not to allow any dust into the reser- voir. • Use fresh SUBARU genuine brake fluid when replacing or refilling the fluid. NOTE: Refer to “PB” section for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General Descrip- tion.>...
  • Page 4 General Description BRAKE Item Standard value Limit Except 17-inch 11 (0.43) 1.5 (0.059) Pad thickness type mm (in) 17-inch type 11 (0.43) 1.5 (0.059) Front brake Except 17-inch 24 (0.94) 22 (0.87) Disc thickness type mm (in) 17-inch type 30 (1.18) 28 (1.10) Disc runout mm (in)
  • Page 5 General Description BRAKE B: COMPONENT 1. FRONT DISK BRAKE • Except for EC, EK, OUTBACK model ( 3) (4 ) (1 ) (7 ) (A ) (17 ) (10 ) ( 11 ) ( 12 ) (B ) ( 14 ) (13) (12) (1 1)
  • Page 6 General Description BRAKE • EC, EK, OUTBACK model ( 2) (5 ) (7 ) ( 8) (17) ( 10) (4 ) ( 11 ) ( 12 ) ( 14) (13) (11 ) ( 16) ( 15) BR-00373 Caliper body Support (17) Bushing Air bleeder screw...

  • Page 7: Rear Disc Brake

    General Description BRAKE 2. REAR DISC BRAKE (34 ) (3 ) ( 4) ( 35 ) ( 14) (1 4) ( 12) (1 0) (4 ) (1 1) (1 4) ( 17) (1 6) (1 1) (13 ) (1 8) (1 9) ( 20) ( 21)

  • Page 8: Master Cylinder

    General Description BRAKE 3. MASTER CYLINDER • LHD model (10) (11) BR-00371 Secondary piston (11) O-ring Filter Cylinder body ⋅ Reservoir tank Cylinder pin Tightening torque: N m (kgf-m, ft-lb) C-ring Seal T: 13 (1.3, 9.6) Primary piston (10) BR-7...
  • Page 9 General Description BRAKE • RHD model (10) (11) BR-00334 Secondary piston (11) O-ring Filter Cylinder body ⋅ Reservoir tank Cylinder pin Tightening torque: N m (kgf-m, ft-lb) C-ring Seal T: 13 (1.3, 9.6) Primary piston (10) BR-8...
  • Page 10 General Description BRAKE 4. FRONT BRAKE PIPES AND HOSE • LHD model (10) BR-00372 ⋅ Model with ABS Clamp Tightening torque: N m (kgf-m, ft-lb) Model with Vehicle dynamics con- Gasket T1: 15 (1.5, 10.8) trol (VDC) ABS control module and hydraulic T2: 18 (1.8, 13.0) control unit (ABSCM&H/U) T3: 19 (1.9, 14.0)
  • Page 11 General Description BRAKE • RHD model (10) BR-00336 ⋅ Model with ABS Gasket Tightening torque: N m (kgf-m, ft-lb) Model with VDC ABS control module and hydraulic T1: 15 (1.5, 10.8) control unit (ABSCM&H/U) T2: 18 (1.8, 13.0) Front brake pipe ASSY Bracket T3: 19 (1.9, 14.0) Two-way connector...
  • Page 12 General Description BRAKE 5. CENTER AND REAR BRAKE PIPES AND HOSE (11) (11) (10) (10) (12) (10) (11) (10) (11) (10) (10) BR-00337 ⋅ Center brake pipe ASSY Rear brake pipe LH Tightening torque: N m (kgf-m, ft-lb) Two-way connector Rear brake hose rear RH T1: 15 (1.5, 10.8) Rear brake pipe ASSY...
  • Page 13 General Description BRAKE 6. BRAKE BOOSTER BR-00335 Brake booster BR-12...
  • Page 14 General Description BRAKE 7. BRAKE PEDAL • LHD MT model BR-00375 ⋅ Brake pedal ASSY Clutch pedal Tightening torque: N m (kgf-m, ft-lb) Stop light switch Clutch pedal pad T1: 8 (0.8, 5.8) Brake pedal pad Clutch switch T2: 18 (1.8, 13.0) BR-13...
  • Page 15 General Description BRAKE • LHD AT model, RHD model BR-00338 ⋅ Brake pedal ASSY Brake pedal pad Tightening torque: N m (kgf-m, ft-lb) Stop light switch T1: 8 (0.8, 5.8) T2: 18 (1.8, 13.0) BR-14...
  • Page 16 • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary re- moval, installation, disassembly and replacement. • Use SUBARU genuine grease etc. or equivalent. Do not mix grease, etc. with that of another grade or from other manufacturers.

  • Page 17: Front Brake Pad

    Front Brake Pad BRAKE 2. Front Brake Pad (4) Attach a rod of less than 12 mm (0.47 in) di- ameter to the shaded area of the brake pad, and A: REMOVAL strike the rod with a hammer to drive brake pad out of place.
  • Page 18 Front Brake Pad BRAKE 3) Apply a thin coat of Molykote AS880N (Part No. 3) Apply a thin coat of Molykote AS880N (Part No. K0779YA010) to the three frictional portions be- K0779YA010) to the three frictional portions be- tween inner shim and outer shim of outer pads. tween inner shim and outer shim of outer pads.
  • Page 19 Front Brake Pad BRAKE • When the pad return spring is deformed or 3. 17-INCH TYPE damaged, replace the brake pad with new one. Check the pad thickness A. BR-00343 BR-00360 (1) Pad return spring Standard 11 (0.43) Pad thickness (2) Supporting surface of pad clip value mm (in)

  • Page 20: Front Disc Rotor

    Front Disc Rotor BRAKE 3. Front Disc Rotor C: INSPECTION 1) Check front wheel bearing play and axial hub A: REMOVAL runout before disc rotor runout limit inspection. <Ref. to DS-15, INSPECTION, Front Axle.> 1. 15-INCH TYPE 2) Secure the disc rotor by tightening five wheel 1) Lift-up the vehicle, and remove the front wheels.

  • Page 21: Front Disc Brake Assembly

    Front Disc Brake Assembly BRAKE 4. Front Disc Brake Assembly 6) Clean mud and foreign particles from the caliper body assembly and the support. A: REMOVAL 2. 16-INCH TYPE 1. 15-INCH TYPE Refer to 15-inch type. <Ref. to BR-20, 15-INCH TYPE, REMOVAL, Front Disc Brake Assembly.>...
  • Page 22 Front Disc Brake Assembly BRAKE 4) Apply a thin coat of Molykote AS880N (Part No. 3) Apply a thin coat of Molykote AS880N (Part No. K0777YA010) to the three frictional portions be- K0777YA010) to the frictional portion between pad tween inner shim and outer shim of outer pads. and inner shim.
  • Page 23 Front Disc Brake Assembly BRAKE 5) Install the pad on support. 7) Using new brake hose gaskets, connect the brake hose. NOTE: Install the pad indicator in proper direction. Tightening torque: ⋅ 18 N m (1.8 kgf-m, 13.0 ft-lb) 8) Bleed air from brake system. C: DISASSEMBLY 1.
  • Page 24 Front Disc Brake Assembly BRAKE CAUTION: CAUTION: Do not damage the cylinder and piston seal Do not force the piston into cylinder. groove. BR-00242 BR-00027 (1) Piston (1) Piston seal (2) Piston boot 6) Remove the guide pin and boot from caliper 6) Position the boot in the grooves on cylinder and body.
  • Page 25 Front Disc Brake Assembly BRAKE 2. 16-INCH TYPE Refer to 15-inch type. <Ref. to BR-23, 15-INCH TYPE, ASSEMBLY, Front Disc Brake Assembly.> 3. 17-INCH TYPE Refer to 15-inch type. <Ref. to BR-23, 15-INCH TYPE, ASSEMBLY, Front Disc Brake Assembly.> E: INSPECTION 1) Repair or replace the faulty parts.

  • Page 26: Rear Brake Pad

    Rear Brake Pad BRAKE 5. Rear Brake Pad 4) Install the caliper body on support. Tightening torque: A: REMOVAL Solid disc brake model 1) Lift-up the vehicle, and then remove the rear ⋅ 27 N m (2.8 kgf-m, 19.9 ft-lb) wheels.

  • Page 27: Rear Disc Rotor

    Rear Disc Rotor BRAKE 6. Rear Disc Rotor (2) If the disc rotor seizes up within hub, drive the disc rotor out by pushing with an 8 mm bolt in A: REMOVAL holes B on the rotor. 1) Lift-up the vehicle, and then remove the rear wheels.
  • Page 28 Rear Disc Rotor BRAKE 4) Set a micrometer 10 mm (0.39 in) inward of the rotor outer perimeter, and then measure the disc rotor thickness. If the thickness of disc rotor is out- side the service limit, replace with a new disc rotor. BR-00036 Standard value Limit...

  • Page 29: Rear Disc Brake Assembly

    Rear Disc Brake Assembly BRAKE 7. Rear Disc Brake Assembly B: INSTALLATION 1) Install the support on housing. A: REMOVAL Tightening torque: CAUTION: ⋅ 53 N m (5.4 kgf-m, 39.1 ft-lb) Do not allow brake fluid to come in contact with 2) Apply a thin coat of Molykote M7439 to the pad vehicle body;...
  • Page 30 Rear Disc Brake Assembly BRAKE 3) Gradually supply compressed air via installation 6) Position the boot in grooves on cylinder and pis- hole of brake hose to force the piston out. ton. BR-00042 BR-00243 (1) Place a 30 mm (1.18 in) wide wooden block (1) Piston here.

  • Page 31: Master Cylinder

    Master Cylinder BRAKE 8. Master Cylinder NOTE: To avoid damaging master cylinder, use aluminum A: REMOVAL plate while holding with vise. CAUTION: 3) Remove the pin which secures the reservoir tank Do not allow brake fluid to come in contact with to master cylinder, and then remove the reservoir vehicle body;...
  • Page 32 Master Cylinder BRAKE 9) Ensure that the inner wall of master cylinder, and D: INSPECTION piston assembly are free of dirt when assembling. Inspect for oil leakage from the master cylinder. Install the primary piston assembly and secondary NOTE: piston assembly, while taking care not to damage After replacing piston kit;...

  • Page 33: Brake Booster

    Brake Booster BRAKE 9. Brake Booster • Use care when placing the brake booster on the floor. A: REMOVAL • Do not change the push rod length. 1) Remove or disconnect the following parts at en- CAUTION: gine compartment. • Do not disassemble the brake booster. (1) Disconnect the connector for brake fluid lev- •...
  • Page 34 Brake Booster BRAKE 3) Connect the operating rod to brake pedal with 8) Measure the clearance between the threaded clevis pin and snap pin. end of stop light switch and stopper. If it is not within specified value, adjust it by adjust- ing the position of stop light switch.
  • Page 35 Brake Booster BRAKE • AIR TIGHTNESS CHECK 3) As engine starts, the brake pedal should move slowly toward the floor. If no change occurs in the Start the engine, and idle it for 1 to 2 minutes, then pedal height, the brake booster is faulty. turn it OFF.
  • Page 36 Brake Booster BRAKE • AIR TIGHTNESS CHECK 2) Stop the engine and watch vacuum gauge. If the vacuum drop range is less than 3.3 kPa (25 1) Start the engine and keep it running until a vac- mmHg, 0.98 inHg) within 15 seconds after stopping uum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A the engine, brake booster is functioning properly.

  • Page 37: Brake Fluid

    RH → (B) Rear LH → (C) Front LH → (D) Rear RH • Fresh Subaru genuine fluid must be used. • Cover the bleeder with cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts.
  • Page 38 Brake Fluid BRAKE 11) Depress the brake pedal with a force of approx- imately 294 N (30 kgf, 66 lb) and hold it there for ap- proximately 20 seconds to check for no entry of air and if pedal height remain same. Visually inspect the bleeder screws and brake pipe joints to make sure that there is no fluid leakage.

  • Page 39: Air Bleeding

    A: PROCEDURE 7) Remove the plastic bag. 8) Install the brake pipes to master cylinder. CAUTION: • Fresh Subaru genuine fluid must be used. Tightening torque: ⋅ • Cover the bleeder with cloth, when loosening 15 N m (1.5 kgf-m, 10.8 ft-lb)
  • Page 40 Air Bleeding BRAKE 3) Slowly depress the brake pedal and keep it de- 7) If the distance is more than specified, there is a pressed. Then, open the air bleeder to discharge possibility that air is in the brake line. Bleed the air together with the fluid.

  • Page 41: Brake Hose

    Brake Hose BRAKE 12.Brake Hose 3) Remove the clamp and remove the brake hose. A: REMOVAL 1. FRONT BRAKE HOSE 1) Separate the brake pipe from brake hose using a flare nut wrench. 2) Remove the clamp, bolt at strut mount, and union bolt.
  • Page 42 Brake Hose BRAKE 3) Install the brake hose to rear brake caliper using CAUTION: a new gasket. Be sure the brake hose is not twisted. 4) Temporarily tighten the flare nut to connect the Tightening torque (Union bolt): ⋅ brake pipe and hose. 18 N m (1.8 kgf-m, 13.0 ft-lb) 5) Fix the brake hose with clamp at wheel apron...

  • Page 43: Brake Pipe

    Brake Pipe BRAKE 13.Brake Pipe A: REMOVAL NOTE: Airbag system wiring harness is routed near the center brake pipe. CAUTION: • All airbag system wiring harness and con- nectors are colored yellow. Do not use the elec- trical test equipment on these circuits. •...

  • Page 44: Brake Pedal

    Brake Pedal BRAKE 14.Brake Pedal 4) Remove the bolts and nuts which secure pedal bracket. A: REMOVAL 1. LHD MT MODEL 1) Remove the steering shaft. 2) Disconnect the connectors (stop light switch) from pedal bracket. 3) Remove the clevis pin which secures lever to push rod.
  • Page 45 Brake Pedal BRAKE CAUTION: If excessive deflection is noted, replace the bushing with a new one. Deflection of brake pedal: Limit 5.0 mm (0.197 in) or less BR-00105 (1) Brake pedal 2) Check the position of pedal pad. Pedal height L: LHD: 150 —...

  • Page 46: Stop Light Switch

    Stop Light Switch BRAKE 15.Stop Light Switch Specified position L: 2 mm (0.079 in) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the stop light switch connector. 3) Loosen the nuts, and unscrew the stop light switch to remove. BR-00109 2) Measure the clearance between the threaded end of stop light switch and stopper.
  • Page 47 Stop Light Switch BRAKE Tightening torque: ⋅ m (0.8 kgf-m, 5.8 ft-lb) BR-00111 (1) Stop light switch (2) Lock nut A (3) Lock nut B (4) Stopper (5) Brake pedal NOTE: Tighten the lock nut B until the clearance between the threaded end of stop light switch and stopper becomes 0 mm (0 inch).

  • Page 48: Diagnosis

    Diagnosis BRAKE 16.Diagnosis A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism Correct or replace. (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose) (2) Entry of air into the hydraulic mechanism Bleed air.
  • Page 49 Diagnosis BRAKE BR-48...

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