1996 SUBARU LEGACY torque

4. Parking Brake (Rear Disc Brake)
G4M0411
1Back plate

2Retainer

3Spring washer

4Lever

5Parking brake shoe (Primary)

6Parking brake show (Secondary)

7Strut spring
8Strut

9Shoe guide plate

10Primary return spring

11Secondary return spring

12Adjusting spring

13Adjuster

14Shoe hold-down cup
15Shoe hold down spring

16Shoe hold down pin

17Adjusting hole cover
Tightening torque: N⋅m (kg-m, ft-lb)
T: 52±6 (5.3±0.6, 38.3±4.3)
G4M0412
A: REMOVAL
1) Remove the two mounting bolts to the disc brake
assembly and remove the disc brake assembly.
2) Suspend the disc brake assembly so that the hose is
not stretched.
3) Remove the disc rotor.
4) Remove shoe return spring from parking brake assem-
bly.
5) Remove front shoe hold down spring and pin with pli-
ers.
6) Remove strut and strut spring.
7) Remove adjuster assembly from parking brake assem-
bly.
8) Remove brake shoe.
9) Remove rear shoe hold-down spring and pin with pliers.
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4-4SERVICE PROCEDURE
4. Parking Brake (Rear Disc Brake)

G4M0416
D: PARKING BRAKE ADJUSTMENT
1. SHOE CLEARANCE ADJUSTMENT
1) Remove adjusting hole cover from back plate.
2) Turn adjusting screw using a slot-type screwdriver until
brake shoe is in close contact with disc rotor.
3) Turn back (downward) adjusting screw 3 or 4 notches.
4) Install adjusting hole cover to back plate.
B4M0050A
2. LEVER STROKE ADJUSTMENT
1) Remove console box lid.
2) Forcibly pull parking brake lever 3 to 5 times.
3) Adjust parking brake lever by turning adjusting nut until
parking brake lever stroke is set at 6 notches with operat-
ing force of 196 N (20 kg, 44 lb).
4) Tighten lock nut.
5) Install console box lid.
Lever stroke:
7 to 8 notches when pulled
with a force of 196 N (20 kg, 44 lb)
Tightening torque (Lock nut):
5.9±1.5 N⋅m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
5. Master Cylinder
A: REMOVAL
1) Thoroughly drain brake fluid from reservoir tank.
2) Disconnect fluid level indicator harness connector.
3) Remove brake pipes from master cylinder.
4) Remove master cylinder mounting nuts, and take out
master cylinder from brake booster.
CAUTION:
Be extremely careful not to spill brake fluid. Brake fluid
spilt on the vehicle body will harm the painted surface;
wipe it off quickly if spilt.
47
4-4SERVICE PROCEDURE
4. Parking Brake (Rear Disc Brake) - 5. Master Cylinder

G4M0416
D: PARKING BRAKE ADJUSTMENT
1. SHOE CLEARANCE ADJUSTMENT
1) Remove adjusting hole cover from back plate.
2) Turn adjusting screw using a slot-type screwdriver until
brake shoe is in close contact with disc rotor.
3) Turn back (downward) adjusting screw 3 or 4 notches.
4) Install adjusting hole cover to back plate.
B4M0050A
2. LEVER STROKE ADJUSTMENT
1) Remove console box lid.
2) Forcibly pull parking brake lever 3 to 5 times.
3) Adjust parking brake lever by turning adjusting nut until
parking brake lever stroke is set at 6 notches with operat-
ing force of 196 N (20 kg, 44 lb).
4) Tighten lock nut.
5) Install console box lid.
Lever stroke:
7 to 8 notches when pulled
with a force of 196 N (20 kg, 44 lb)
Tightening torque (Lock nut):
5.9±1.5 N⋅m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
5. Master Cylinder
A: REMOVAL
1) Thoroughly drain brake fluid from reservoir tank.
2) Disconnect fluid level indicator harness connector.
3) Remove brake pipes from master cylinder.
4) Remove master cylinder mounting nuts, and take out
master cylinder from brake booster.
CAUTION:
Be extremely careful not to spill brake fluid. Brake fluid
spilt on the vehicle body will harm the painted surface;
wipe it off quickly if spilt.
47
4-4SERVICE PROCEDURE
4. Parking Brake (Rear Disc Brake) - 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.
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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.
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4-4SERVICE PROCEDURE
6. Brake Booster

G4M0426
7. Brake Hose
A: REMOVAL
1) Separate brake pipe from brake hose.
(Always use flare nut wrench and be careful not to deform
flare nut.)
2) Pull out clamp to remove brake hose.
3) Remove clamp at strut and union bolt.
G4M0427
B: INSTALLATION
1. FRONT BRAKE HOSE
1) Route end of brake hose (on caliper side) through hole
in brake hose bracket at strut location.
2) Tighten end of brake hose at caliper using a union bolt.
Tightening torque (Union bolt):
18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
3) Secure middle fitting of brake hose to bracket at strut
location using a clamp.
4) Position disc in straight-forward direction and route
brake hose through hole in bracket on wheel apron side.
CAUTION:
Be sure brake hose is not twisted.
5) Temporarily tighten flare nut to connect brake pipe and
hose.
6) Fix brake hose with clamp at wheel apron bracket.
7) While holding hexagonal part of brake hose fitting with
a wrench, tighten flare nut to the specified torque.
Tightening torque (Brake pipe flare nut):
15
+3
2N⋅m (1.5+0.3
0.2kg-m, 10.8+2.2
1.4ft-lb)
8) Bleed air from the brake system.
2. REAR BRAKE HOSE
1) Pass brake hose through the hole of bracket, and lightly
tighten flare nut to connect brake pipe.
2) Insert clamp upward to fix brake hose.
3) Perform the same procedures as before mentioned in
steps 7) and 8).
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4-4SERVICE PROCEDURE
7. Brake Hose

C: INSTALLATION
1) Install PHV onto side frame.
Tightening torque:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
2) Connect brake pipes to PHV.
Tightening torque:
15
+3
2N⋅m (1.5+0.3
0.2kg-m, 10.8+2.2
1.4ft-lb)
CAUTION:
Confirm that brake pipes are not deformed and/or dam-
aged. Replace them with new ones if necessary.
3) Install PHV cable to PHV stay.
CAUTION:
If cable clamp (and clips) is damaged, replace it with a
new one.
4) Connect PHV cable with clips.
NOTE:
Avoid sharp bending of PHV cable as it may cause break-
age.
5) Install PHV cable onto cable bracket on engine.
6) Apply grease to the following points.

Hook portion of return spring

Cable end portion of lever
Grease:
SUNLIGHT 2 (Part No. 003602010)
7) Be sure to bleed air from the system.
CAUTION:
After replacing PHV cable or clutch cable with new
one, operate clutch pedal about 30 times as a run-
ning-in operation prior to adjustment.
D: ADJUSTMENTS
Confirm stopping and starting performances by activating
hill holder on an uphill road of 3°or higher inclination.
(1) If vehicle does not stop;
Tighten adjusting nut of PHV cable.
(2) If vehicle does not start properly;

Case A—When hill holder is released later than
engagement of clutch pedal (Engine tends to stall.):
Loosen adjusting nut gradually until smooth starting
is enabled.

Case B—When hill holder is released earlier than
engagement of clutch pedal (Vehicle slips down
slightly.):
Tighten adjusting nut so that hill holder is released
later than engagement of clutch pedal (status in Case
A). Then make adjustment the same as in Case A.
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4-4SERVICE PROCEDURE
8. Hill Holder

G4M0429
NOTE:
Whenever turning adjusting nut, prevent PHV cable from
revolving as shown in Figure.
9. Parking Brake Lever
A: REPLACEMENT
1) Remove console box from front floor.
2) Disconnect electric connector for parking brake switch.
3) Loosen parking brake adjuster, and remove inner cable
end from equalizer.
4) Remove parking brake lever.
5) Install parking brake lever in the reverse order of
removal.
Tightening torque (Lever installing bolt and nut):
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B4M0050A
6) Adjust parking brake lever by turning adjusting nut until
parking brake lever stroke is set at 7 to 8 notches with
operating force of 196 N (20 kg, 44 lb).
7) Tighten lock nut.
Tightening torque (Lock nut):
5.9±1.5 N⋅m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
59
4-4SERVICE PROCEDURE
8. Hill Holder - 9. Parking Brake Lever