1996 SUBARU LEGACY brake light

Tightening torque:
186±20 N⋅m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
Use a new axle nut.
Always tighten axle nut before installing wheel on
vehicle. If wheel is installed and comes in contact with
ground when axle nut is loose, wheel bearings may be
damaged.
Be sure to tighten axle nut to specified torque. Do
not overtighten it as this may damage wheel bearing.
12) Install O-ring to hub cap flange, and install hub cap by
lightly tapping it with a plastic-faced hammer.
13) Install wheel and tighten wheel nuts to specified
torque.
Tightening torque (Wheel nut):
88±10 N⋅m (9±1 kg-m, 65±7 ft-lb)
4. Front and Rear Drive Shafts
A: REMOVAL
1. FRONT DRIVE SHAFT
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands (rigid
racks), and remove front wheel cap and wheels.
3) Unlock axle nut.
4) While depressing brake pedal, remove axle nut using a
socket wrench.
CAUTION:
Be sure to loosen and retighten axle nut after remov-
ing wheel from vehicle. Failure to follow this rule may
damage wheel bearings.
5) Disconnect stabilizer link from transverse link.
6) Disconnect transverse link from housing.
G4M0279
7) Remove spring pin which secures transmission spindle
to DOJ.
CAUTION:
Use a new spring pin.
28
4-2SERVICE PROCEDURE
3. Rear Axle (FWD) - 4. Front and Rear Drive Shafts

Whine or growl (continuous or
intermittent)
While engine is running with/
without steering turned.Loosened installation of oil pump,
oil pump bracketRetighten.
*8
Abnormal inside of oil pump, hoseReplace oil pump, hose, if the
noise can be heard when running
as well as stand still.
Torque converter growl
air conditioner compression growlRemove power steering pulley
belt and confirm.
Creaking noise (intermittent)
While engine is running with
steering turned.Abnormal inside of gearboxReplace bad parts of gearbox.
Abnormal bearing for steering
shaftApply grease or replace.
*9
Generates when turning steering
wheel with brake (service or park-
ing) applied.If the noise goes off when brake
is released, it is normal.
*10
Vibration
While engine is running with/
without steering turned.
Too low engine speed at startAdjust and instruct customers.
Vane pump aerationFix wrong part.
Vent air.
Damaged valve in oil pump, gear-
boxReplace oil pump, bad parts of
gearbox.
Looseness of play of steering,
suspension partsRetighten.
*8 Oil pump makes whine or growl noise slightly due to its mechanism. Even if the noise can be heard when steering wheel
is turned at stand still there is no abnormal function in the system provided that the noise eliminates when the vehicle is
running.
*9 When stopping with service brake and/or parking brake applied, power steering can be operated easily due to its light
steering effort. If doing so, the disk rotates slightly and makes creaking noise. The noise is generated by creaking between
the disk and pads. If the noise goes off when the brake is released, there is no abnormal function in the system.
*10 There may be a little vibration around the steering devices when turning steering wheel at standstill, even though the com-
ponent parts are properly adjusted and have no defects.
Hydraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of com-
bined conditions, i.e., road surface and tire surface, engine speed and turning speed of steering wheel, fluid temperature
and braking condition.
This phenomena does not indicate there is some abnormal function in the system.
The vibration can be known when steering wheel is turned repeatedly at various speeds from slow to rapid step by step
with parking brake applied on concrete road and in“D”range for automatic transmission vehicle.
96
4-3DIAGNOSTICS
1. Power Steering

9. BREAKAGE OF HOSES
Pressure hose burstExcessive holding time of relief
statusInstruct customers.
Malfunction of relief valveReplace oil pump.
Poor cold characteristic of fluidReplace fluid.
Forced out return hosePoor connectionCorrect.
Poor holding of clipRetighten.
Poor cold characteristic of fluidReplace fluid.
Fluid bleeding out of hose slightlyWrong layout, tensionedReplace hose.
Excessive play of engine due to
deterioration of engine mounting
rubberReplace defective parts.
Improper stop position of pitching
stopperReplace defective parts.
*11
Crack on hose
Excessive holding time of relief
statusReplace.
Instruct customer.
Excessive tightening torque for
return hose clipReplace.
Power steering fluid, brake fluid,
engine oil, electrolyte adhere on
the hose surfaceReplace.
Pay attention on service work.
Too many times use in extremely
cold weatherReplace.
Instruct customers.
*11 Although surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for
low temperature brittleness, they are likely to be damaged chemically by brake fluid, battery electrolyte, engine oil and
automatic transmission fluid and their service lives are to be very shortened. It is very important to keep the hoses free
from before mentioned fluids and to wipe out immediately when the hoses are adhered with the fluids.
Since resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or
cold conditions for the hoses and their service lives are shortening accordingly, it is necessary to perform careful inspec-
tion frequently when the vehicle is used in hot weather areas, cold weather area and/or a driving condition in which many
steering operations are required in short time. Particularly continuous work of relief valve over 5 seconds causes to reduce
service lives of the hoses, the oil pump, the fluid, etc. due to over heat.
So, avoid to keep this kind of condition when servicing as well as driving.
99
4-3DIAGNOSTICS
1. Power Steering

B: SERVICE DATA
ITEM STANDARD SERVICE LIMIT
Front brakePad thickness
(including back metal)17 mm (0.67 in) 7.5 mm (0.295 in)
Disc thickness 24 mm (0.94 in) 22 mm (0.87 in)
Disc runout—0.075 mm (0.0030 in)
Rear brake (Disc type)Pad thickness
(including back metal)15 mm (0.59 in) 6.5 mm (0.256 in)
Disc thickness 10 mm (0.39 in) 8.5 mm (0.335 in)
Disc runout—0.10 mm (0.0039 in)
Rear brake (Drum type)Inside diameter 228.6 mm (9 in) 230.6 mm (9.08 in)
Lining thickness 4.1 mm (0.161 in) 1.5 mm (0.059 in)
Rear brake (Disc type
parking)Inside diameter 170 mm (6.69 in) 171 mm (6.73 in)
Lining thickness 3.2 mm (0.126 in) 1.5 mm (0.059 in)
Parking brake Lever stroke 7 to 8 notches/196N (20 kg, 44 lb)
Without ABS and TCS With ABS and TCS
Brake boosterBrake pedal force Fluid pressure
Brake fluid pressure
without engine running147 N
(15 kg, 33 lb)785 kPa
(8 kg/cm
2, 114 psi)588 kPa
(6 kg/cm2, 85 psi)
294 N
(30kg, 66 lb)2,158 kPa
(22 kg/cm
2, 313 psi)1,667 kPa
(17 kg/cm2, 242 psi)
Brake fluid pressure with
engine running and
vacuum at 66.7 kPa (500
mmHg, 19.69 inHg)147 N
(15 kg, 33 lb)5,492 kPa
(56 kg/cm
2, 796 psi)5,394 kPa
(55 kg/cm2, 782 psi)
294 N
(30kg, 66 lb)8,434 kPa
(86 kg/cm
2, 1,223 psi)10,003 kPa
(102 kg/cm2, 1,450 psi)
C: RECOMMENDED BRAKE FLUID
FMVSS No. 116, fresh DOT3 or 4 brake fluid
CAUTION:

Avoid mixing brake fluid of different brands to pre-
vent the fluid performance from degrading.

When brake fluid is supplemented, be careful not to
allow any dust into the reservoir.

Use fresh DOT3 or 4 brake fluid when replacing or
refilling the fluid.
D: BRAKE FLUID LEVEL INDICATOR
Reserve tank with level indicator:
Residual fluid quantity at light ON
Approx. 80 cm
3(4.88 cu in)
Tank capacity
190 cm
3(11.59 cu in)
8
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

B: DISASSEMBLY
1. PRECAUTIONS FOR DISASSEMBLING
1) Remove mud and dirt from the surface of brake master
cylinder.
2) Prepare tools necessary for disassembly operation, and
arrange them neatly on work bench.
3) Clean work bench.
4) Tools for disassembly operation:

1 Phillips screwdriver

1 C-ring pliers
G4M0418
2. DISASSEMBLING PROCEDURE
1) Remove reserve tank.
2) Remove supply valve stopper. (only vehicle equipped
with ABS)
3) Remove filter and cylinder pin. (only vehicle equipped
with TCS)
4) Remove C-ring with C-ring pliers pushing in primary
piston slightly.
NOTE:
Piston may jump out from master cylinder.
5) Extract primary piston assembly and secondary piston
assembly.
CAUTION:

Do not disassemble the piston assembly; otherwise,
the spring set value may be changed.

Use brake fluid or methanol to wash inside wall of
cylinder, pistons and piston cups. Be careful not to
damage parts when washing. If methanol is used for
washing, do not dip rubber parts, such as piston cups,
in it for more than 30 seconds; otherwise, they may
become swelled.
C: INSPECTION
If any damage, deformation, wear, swelling, rust, and other
faults are found on the primary piston assembly, second-
ary piston assembly, supply valve stopper, or gasket,
replace the faulty part.
CAUTION:

The primary and secondary pistons must be
replaced as complete assemblies.

The service limit of the clearance between each pis-
ton and the master cylinder inner dia. is 0.11 mm
(0.0043 in).

When handling parts, be extremely careful not to
damage or scratch the parts, or let any foreign matter
get on them.
48
4-4SERVICE PROCEDURE
5. Master Cylinder

D: ASSEMBLY
1. PRECAUTIONS FOR ASSEMBLING
1) When assembling, be sure to use recommended brake
fluid.
2) Ensure that the inside wall of cylinder, pistons, and pis-
ton cups are free from dirt when assembling.
3) Be extremely careful not to damage, scratch, or dent
cylinder inside wall, pistons, and piston cups.
4) Do not drop parts. Never attempt to use any part that
has been dropped accidentally.
2. ASSEMBLING OPERATION
1) Assembling piston assembly:
Apply recommended brake fluid to inside wall of cylinder,
and to outer surface of piston assembly, and install piston
assemblies carefully into cylinder.
2) Assembling supply valve stopper or cylinder pin:
After installing piston into cylinder, push primary piston in
about 10 mm (0.39 in), using a rod, such as push rod then
assemble gasket and supply valve stopper or cylinder pin.
Tightening torque:
2.2±0.7 N⋅m (0.225±0.075 kg-m, 1.6±0.5 ft-lb)
CAUTION:
If the gasket and supply valve stopper are assembled
without pushing in the primary piston, scratches may
be caused on the secondary piston, and no pressure
may be built up in the secondary side. To avoid such
an error, be sure to push in the primary piston before
assembling these parts.
3) Assembling C-ring:
With primary piston pushed in slightly, attach C-ring by
using C-ring pliers.
NOTE:
After assembling, ensure that the C-ring is fitted securely
in the ring groove.
E: INSTALLATION
To install the master cylinder to the body, reverse the
sequence of removal procedure.
Tightening torque:
Master cylinder mounting nut
14±4 N⋅m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
Piping flare nut
15
+3
2N⋅m (1.5+0.3
0.2kg-m, 10.8+2.2
1.4ft-lb)
CAUTION:
Be sure to use recommended brake fluid.
49
4-4SERVICE PROCEDURE
5. Master Cylinder

B4M0616A
B4M0617A
7) Adjust operating rod of brake booster.
Standard: L
145.3 mm (5.72 in)
If it is not in specified value, adjust it by adjusting brake
booster operating rod.
8) Measure the clearance between threaded end of stop
light switch and stopper.
If it is not in specified value, adjust it by adjusting position
of stop light switch.

1Stop light switch

2Stopper

3Brake pedal
CAUTION:
Be careful not to rotate stop light switch.
Stop light switch clearance: A
0.3 mm (0.012 in)
9) Apply grease to operating rod connecting pin to prevent
it from wearing.
10) Bleed air from brake system.
Tightening torque (Air bleeder screw):
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
11) Conduct road tests to ensure brakes do not drag.
C: OPERATION CHECK
CAUTION:
When checking operation, be sure to securely apply
the hand brake.
1. CHECKING WITHOUT USING GAUGES
This method cannot determine the exact portion which has
failed, but it can provide a rough understanding of the
nature of the failure if checking is conducted in accordance
with the following procedures.
51
4-4SERVICE PROCEDURE
6. Brake Booster

G4M0744
2. AIR TIGHTNESS CHECK
Start engine, and run it for 1 to 2 minutes, then turn it off.
Depress brake pedal several times applying the same
pedal force as that used in ordinary braking operations.
The pedal stroke should be greatest on the 1st depression,
and it should become smaller with each successive
depression. If no change occurs in the pedal height while
in a depressed state, brake booster is faulty.
NOTE:

In the event of defective operation, inspect the condition
of the check valve and vacuum hose.

Replace them if faulty and conduct the test again.

If no improvement is observed, check precisely with
gauges.
G4M0914
3. OPERATION CHECK
1) With engine off, depress brake pedal several times
applying the same pedal force and make sure that the
pedal height does not vary with each depression of the
pedal.
2) With brake pedal depressed, start engine.
3) As engine starts, brake pedal should move slightly
toward the floor. If no change occurs in the pedal height,
brake booster is faulty.
NOTE:
If faulty, check precisely with gauges.
4. LOADED AIR TIGHTNESS CHECK
Depress brake pedal while engine is running, and turn off
engine while the pedal is still depressed. Keep the pedal
depressed for 30 seconds; if no change occurs in the pedal
height, brake booster is functioning normally; if the pedal
height increases, it is faulty.
NOTE:
If faulty, check precisely with gauges.
52
4-4SERVICE PROCEDURE
6. Brake Booster