Subaru Legacy (2005 year). Service manual — part 829

BR-45

BRAKE

Stop Light Switch

15.Stop Light Switch

A: REMOVAL

1) Disconnect the ground cable from battery.
2) Disconnect the stop light switch connector.
3) Loosen the nuts, unscrew the stop light switch,
and remove stop light switch.

B: INSTALLATION

1) Screw the stop light switch onto a bracket and
secure it temporarily with a nut.
2) Adjust the stop light switch position, and then
tighten the nut.
<Ref. to BR-46, ADJUSTMENT, Stop Light
Switch.>

Tightening torque:

8 N

⋅

m (0.8 kgf-m, 5.8 ft-lb)

C: INSPECTION

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

Specified position L:

2 mm (0.079 in)

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

CAUTION:
Be careful not to rotate the stop light switch.

Stop light switch clearance A:

0.3 mm (0.012 in)

3) If it is not within the specification, adjust it by ad-
justing the position of stop light switch.

CAUTION:
Be careful not to rotate the stop light switch.

(1) Stop light switch

(1)

BR-00107

T

BR-00108

(1) Stop light switch

(2) Stopper

(3) Brake pedal

L

BR-00109

A

(1)

(2)

(3)

BR-00110

BR-46

BRAKE

Stop Light Switch

D: ADJUSTMENT

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

Tightening torque:

8 N

⋅

m (0.8 kgf-m, 5.8 ft-lb)

NOTE:
Tighten the lock nut B until the clearance between
the threaded end of stop light switch and stopper
becomes 0 mm (0 inch). Hold the stop light switch
to prevent turning, and then loosen the lock nut B
approx. 60

°. The clearance (A) becomes 0.3 mm

(0.012 in).

(1) Stop light switch

(2) Lock nut A

(3) Lock nut B

(4) Stopper

(5) Brake pedal

(5)

(4)

(1)

A

(2)

(3)

BR-00111

BR-47

BRAKE

General Diagnostic Table

16.General Diagnostic Table

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.

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

Replace, grind or clean.

(4) Improper operation of master cylinder, disc caliper,
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, and 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

Rectify or replace.

(5) Improper tire inflation

Adjust to correct pressure.

(6) Disordered wheel alignment

Adjust alignment.

(7) Loosened back plate or the support installing bolts

Retighten to specified torque.

(8) Faulty wheel bearing

Replace.

(9) Trouble in 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 air.

(2) Excessive play in the master cylinder push rod

Adjust.

(3) Fluid leakage from the hydraulic mechanism

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

(4) Improper lining contact or worn lining

Correct or replace.

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) Improper disc caliper operation

Correct or replace.

(7) Faulty wheel bearing

Replace.

5. Brake noise (1)
(creak sound)

(1) Hardened or deteriorated brake pad

Replace the pad.

(2) Worn brake pad

Replace the pad.

(3) Loosened back plate or the support installing bolts

Retighten to specified torque.

(4) Loose wheel bearing

Retighten to specified torque.

(5) Dirty rotor

Clean the rotor, or clean and replace brake
assembly.

6. Brake noise (2)
(hissing sound)

(1) Worn brake pad

Replace the pad.

(2) Improper installed pad

Correct or replace the pad.

(3) Loose or bent rotor

Retighten or replace.

7. Brake noise (3)
(click sound)

Excessively worn pad or the support

Replace the pad or the support.

BR-48

BRAKE

General Diagnostic Table