Subaru Legacy (2005 year). Service manual — part 818

BRAKE

BR

Page

1.

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

2.

Front Brake Pad . . . . . . . . . . . . . . . . . . . . . . 16

3.

Front Disc Rotor . . . . . . . . . . . . . . . . . . . . . . 19

4.

Front Disc Brake Assembly. . . . . . . . . . . . . . . . . ...20

5.

Rear Brake Pad. . . . . . . . . . . . . . . . . . . . . . .25

6.

Rear Disc Rotor. . . . . . . . . . . . . . . . . . . . . . .26

7.

Rear Disc Brake Assembly . . . . . . . . . . . . . . . . . ...28

8.

Master Cylinder . . . . . . . . . . . . . . . . . . . . . . .30

9.

Brake Booster . . . . . . . . . . . . . . . . . . . . . . ...33

10.

Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . 37

11.

Air Bleeding. . . . . . . . . . . . . . . . . . . . . . . ...38

12.

Brake Hose . . . . . . . . . . . . . . . . . . . . . . . ...40

13.

Brake Pipe. . . . . . . . . . . . . . . . . . . . . . . . .42

14.

Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . ...43

15.

Stop Light Switch . . . . . . . . . . . . . . . . . . . . . ..45

16.

General Diagnostic Table. . . . . . . . . . . . . . . . . . ..47

BR-2

BRAKE

General Description

1. General Description

A: SPECIFICATION

NOTE:
Refer to “PB” section for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General Descrip-
tion.>

Model

2.0 i, 2.5 i

3.0 R (EH model), OUT-

BACK 2.5 i, OUTBACK

3.0 R

2.0 GT, 3.0 R (Except for

EH model)

Front disc
brake

Size

15-inch type

16-inch type

17-inch type

Type

Disc (Floating type, ventilated)

Effective disc diameter

mm (in)

228 (8.98)

244 (9.61)

261 (10.28)

Disc thickness

× Outer

diameter

mm (in)

24

× 277 (0.94 × 10.91)

24

× 294 (0.94 × 11.57)

30

× 316 (1.18 × 12.44)

Effective cylinder diameter

42.8 (1.685)

× 2

Pad dimensions
(length

× width × thick-

ness)

mm (in)

117.8

× 50.5 × 11.0 (4.638 × 1.988 × 0.433)

130.0

× 53.5 × 11.0

(5.118

× 2.106 × 0.433)

Clearance adjustment

Automatic adjustment

Rear disc
brake

Size

15-inch type

Type

Disc (Floating type, solid)

Disc (Floating type, venti-

lated)

Effective disc diameter

mm (in)

238 (9.37)

254 (10.0)

Disc thickness

× Outer

diameter

mm (in)

10

× 274 (0.39 × 10.79)

18

× 290 (0.71 × 11.42)

Effective cylinder
diameter

mm (in)

38.1 (1.500)

Pad dimensions
(length

× width × thick-

ness)

mm (in)

92.0

× 33.0 × 9.0 (3.622 × 1.299 × 0.354)

82.4

× 33.7 × 9.0

(3.244

× 1.327 × 0.354)

Clearance adjustment

Automatic adjustment

Master
cylinder

Type

Tandem

Effective diameter

mm (in)

23.8 (15/16)

Reservoir type

Sealed type

Brake fluid reservoir
capacity

cm

3

(cu

in)

205 (12.51)

Brake
booster

Type

Vacuum suspended

Effective diameter

mm (in)

208 + 229 (8.19 + 9.02)

Brake line

Dual circuit system

Brake fluid
CAUTION:
• Avoid mixing brake fluid of different
brands to prevent fluid performance from
degrading.
• When filling brake fluid, be careful not to
allow any dust into the reservoir.
• Use fresh brake fluid when replacing or
refilling fluid.

FMVSS No. 116, DOT3

BR-3

BRAKE

General Description

Item

Specification

Limit

Front brake

Pad thickness

mm (in)

Except 17-inch
type

11 (0.43)

1.5 (0.059)

17-inch type

11 (0.43)

1.5 (0.059)

Disc thickness

mm (in)

Except 17-inch
type

24 (0.94)

22 (0.87)

17-inch type

30 (1.18)

28 (1.10)

Disc runout

mm (in)

—

0.05 (0.0020)

Rear brake (Disc
type)

Pad thickness

mm (in)

Solid disc

9.0 (0.354)

1.5 (0.059)

Ventilated disc

9.0 (0.354)

1.5 (0.059)

Disc thickness

mm (in)

Solid disc

10 (0.39)

8.5 (0.335)

Ventilated disc

18 (0.71)

16 (0.63)

Disc runout

mm (in)

—

0.05 (0.0020)

Parking brake

Inside diameter

mm (in)

170 (6.69)

171 (6.73)

Lining thickness

mm (in)

3.2 (0.126)

1.5 (0.059)

Lever stroke

5 — 6 notches/200 N (20 kgf, 45 lbf)

Brake pedal force

N (kgf, lbf)

Fluid pressure kPa (kgf/cm

2

, psi)

15-inch type

16-inch type

17-inch type

Brake
booster

Brake fluid pressure without
engine running

147 (15, 33)

545 (6, 79)

294 (30, 66)

1,564 (16, 227)

Brake fluid pressure with
engine running and vacuum
at 66.7 kPa (500 mmHg,
19.69 inHg)

147 (15, 33)

6,003 (61, 871)

5,381 (55, 780)

4,963 (51, 720)

294 (30, 66)

11,273 (115, 1,635) 10,982 (112, 1,593) 10,055 (103, 1,458)

Brake pedal

Free play

mm (in)

0.5 — 2 (0.02 — 0.08)
[When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lbf).]

BR-4

BRAKE

General Description

B: COMPONENT

1. FRONT DISK BRAKE

• Except for EC, EK, OUTBACK model

(A)

15, 16-inch type

(B)

17-inch type

(1)

Caliper body

(9)

Support

(17)

Bushing

(2)

Air bleeder screw

(10)

Pad clip

(3)

Guide pin (Green)

(11)

Outer shim

Tightening torque: N

⋅

m (kgf-m, ft-lb)

(4)

Pin boot

(12)

Inner shim

T1: 8 (0.8, 5.9)

(5)

Piston seal

(13)

Pad (Outside)

T2: 27 (2.8, 19.9)

(6)

Piston

(14)

Pad (Inside)

T3: 80 (8.2, 59)

(7)

Piston boot

(15)

Disc rotor

(8)

Lock pin (Yellow)

(16)

Disc cover

BR-00332

( 1 )

( 2 )

( 3 )

( 4 )

( 4 )

( 1 7 )

( 1 0 )

( 1 1 )

( 1 1 )

( 1 2 )

( 1 2 )

( 1 6 )

( A )

( B )

( 1 3 )

( 1 4 )

( 1 5 )

( 5 )

( 6 )

( 7 )

( 9 )

( 8 )

T2

T3

( 1 1 )

( 1 1 )

( 1 2 )

( 1 2 )

( 1 3 )

( 1 4 )

( 1 3 )

T1