2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
Contents
1. Remove the rear shoe hold down spring and pin with pliers 11 Remove the parking brake cable from lever PB 00014 1 Parking brake cable 2 Lever 12 Using a flat tip screwdriver raise the retainer Remove the parking lever and washer from brake shoe PB 7 Parking Brake Assembly Rear Disc Brake PARKING 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 e Six contact surfaces of shoe rim and back plate packing e Contact surface of shoe wave and anchor pin e Contact surface of lever and strut e Contact surface of shoe wave and adjuster as sembly e Contact surface of shoe wave and strut e 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 PB 00039 1 Primary return spring 2 Anchor pin 3 Plate 4 Primary shoe 5 Shoe hold down pin and shoe hold down cup 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 fron2. 2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS 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 ABS ABS 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 TRANSFER CASE TC DRIVE SHAFT SYSTEM DS ABS DIAGNOSTICS ABS diag VEHICLE DYNAMICS CONTROL VDC VDC VEHICLE DYNAMICS CONTROL VDC ypc diag DIAGNOSTICS BRAKE BR PARKING BRAKE PB POWER ASSISTED SYSTEM POWER STEERING 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 G2320GE6 SSS SSS PARKING BRAKE dd rd ho Page General Des PN 2 Parking Brake LEN 5 Parking Brake Gabl um uingsmnsmmmv knuste avkadat 6 Parking Brake Assembly Rear Disc Brake rnrrnnnnnnnnnnnnnrrrrnnnnnnnnnnnrrrnnnne 7 General D
3. ce is maladjusted Adjustment Return spring is faulty Replace Return spring is faulty Replace Shoe hold down spring is faulty Replace Brake drag Noise from brake PB 10
4. iagnostic Table rrrrrnnnnnnronnnnnavnnnnrrnrnnnnnnnnrnnnnnnnnennnrnrrnnnnnnnnene 10 PARKING BRAKE 1 General Description A SPECIFICATION Type General Description Mechanical on rear brakes drum in disc Effective drum diameter mm in 170 6 69 Lining dimensions length x width x mm in thickness 163 1 x 30 0 x 3 2 6 421 x 1 181 x 0 126 Clearance adjustment Manual adjustment Lever stroke notches N kgf Ib 5 to 6 200 20 4 45 PB 2 General Description PARKING BRAKE B COMPONENT 1 PARKING BRAKE REAR DISC BRAKE PB 00048 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 3 General Description PARKING BRAKE 2 PARKING BRAKE CABLE T1 PB 00056 5 Bracket 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 hand
5. ling the parking brake lever upward count the notches Lever stroke 5 to 6 notches when pulled with a force of 200 N 20 4 kgf 45 Ib If it is not within the specified value adjust the park ing brake lt Ref to PB 9 ADJUSTMENT Parking Brake Assembly Rear Disc Brake gt D ADJUSTMENT Adjust the parking lever stroke lt Ref to PB 9 LE VER STROKE ADJUSTMENT Parking Brake As sembly Rear Disc Brake gt PB 5 PARKING BRAKE Parking Brake Cable PARKING BRAKE 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 lt Ref to PB 5 REMOVAL Parking Brake Lever gt 5 Roll up the floor mat and remove the clamps PB 00043 6 Remove the inner cable end from equalizer PB 00008 1 Equalizer 2 Inner cable end 7 Lift up the vehicle and then remove the rear wheels 8 Remove the parking brake cable from rear brake lt Ref to PB 7 REMOVAL Parking Brake Assembly Rear Disc Brake gt 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 le
6. ng 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 SA 3 PB 00032 Adjusting screw Adjusting hole cover rubber Flat tip screwdriver Back plate 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 lt Ref to PB 9 LEVER STROKE ADJUSTMENT Parking Brake Assembly Rear Disc Brake gt PARKING BRAKE 2 LEVER STROKE 1 Adjust the shoe clearance before lever stroke adjustment lt Ref to PB 9 SHOE CLEARANCE ADJUSTMENT Parking Brake Assembly Rear Disc Brake gt 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 with a force of 200 N 20 4 kgf 45 Ib oe PB 00054 1 Adjusting nut Self locking nut 5 Check there is no brake drag 6 Install the parking lever cover PB 9 General Diagnostic Table PARKING BRAKE 5 General Diagnostic Table A INSPECTION Symptom Possible cause Remedy Parking brake lever is maladjusted Adjustment Parking brake cable does not move Repair or replace Parking brake shoe clearan
7. s because each part on the vehicle is hot after running e 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 e 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 e Keep grease etc away from parking brake shoes 1 Parking brake lever 6 Clamp 2 Parking brake switch 7 3 Adjusting nut Self locking nut 8 Clamp 4 Equalizer 9 5 PB 4 Parking brake cable RH T2 33 3 4 24 3 Parking brake cable LH Tightening torque N m kgf m ft lb 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 lt Ref to PB 5 ADJUST MENT Parking Brake Lever gt C INSPECTION 1 Operate the parking brake lever 3 to 4 times and return the lever fully 2 While pul
8. t e Install the adjuster assembly with screw on left side arty Cay gon LI PB 00016 1 LH 7 Install the secondary return spring and adjusting spring 1 2 3 Lever Secondary brake shoe Strut spring Strut Return spring Adjuster Shoe hold down cup Adjusting spring oa A 6 7 8 8 Adjust the parking brake lt Ref to PB 9 AD JUSTMENT Parking Brake Assembly Rear Disc Brake gt 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 200 m 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 a eS eS eS eee PB 8 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 parki
9. ver stroke lt Ref to PB 5 ADJUST MENT Parking Brake Lever gt 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 PB 6 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 BR 00346 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 BR 00155 Adjuster Adjusting hole cover rubber Flat tip screwdriver Back plate PARKING BRAKE 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 BR 00036 5 Remove the shoe return spring from parking brake assembly 6 Remove the front shoe hold down spring and pin PB 00028 7 Remove the strut and strut spring 8 Remove the adjuster assembly from parking brake assembly 9 Remove the brake shoe 10
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