2004 SUBARU FORESTER wheel

PM-32
PERIODIC MAINTENANCE SERVICE
Brake Fluid
19.Brake Fluid
A: REPLACEMENT
1) Lift-up the vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from master cylinder
with syringe.
4) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or DOT4 brake
fluid
CAUTION:
 Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
 Be careful not to allow dirt or dust to get into
the reservoir tank.
Bleeding sequence (1) → (2) → (3) → (4)
5) Install one end of a vinyl tube onto the air bleeder
and insert the other end of the tube into a container
to collect the brake fluid.
CAUTION:
 Cover the bleeder with waste cloth, when
loosening it, to prevent brake fluid from being
splashed over surrounding parts. During the bleeding operation, keep the
brake reservoir tank filled with brake fluid to
eliminate entry of air.
 The brake pedal operating must be very slow.
 For convenience and safety, two people
should do the work.
NOTE:
The amount of brake fluid required is approx. 500
m2 (16.9 US fl oz, 17.6 Imp fl oz) for total brake
system.
6) Instruct your co-worker to depress the brake
pedal slowly two or three times and then hold it de-
pressed.
7) Loosen the bleeder screw approx. 1/4 turn until a
small amount of brake fluid drains into container,
and then quickly tighten the screw.
8) Repeat steps 6) and 7) above until there are no
air bubbles in the drained brake fluid and new fluid
flows through vinyl tube.
NOTE:
Add brake fluid as necessary while performing the
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold
brake pedal depressed and tighten the bleeder
screw and install bleeder cap.
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
10) Bleed air from each wheel cylinder by following
the previous 5 steps.
11) Depress the brake pedal with a force of approx.
294 N (30 kgf, 66 lb) and hold it there for approx. 20
seconds. At this time check the pedal to see if it
makes any unusual movement. Visually inspect the
bleeder screws and brake pipe joints to make sure
that there is no fluid leakage.
12) Install the wheels, and drive the vehicle for a
short distance between 2 to 3 km (1 to 2 miles) to
make sure that brakes are operating properly.
(1) Front right
(2) Rear left
(3) Front left
(4) Rear right
(5) Secondary
(6) Primary
(1) (4)
(2) (3) (5) (6)
PM-00047
PM-00048

PM-33
PERIODIC MAINTENANCE SERVICE
Disc Brake Pads and Discs
20.Disc Brake Pads and Discs
A: INSPECTION
1. DISC BRAKE PAD AND DISC
1) Lift-up the vehicle. Then remove the wheels.
2) Visually check the pad thickness through inspec-
tion hole of disc brake assembly. Replace the pad if
necessary.
CAUTION:
When replacing a pad, always replace the pads
for both the right and left wheels at the same
time. Also replace the pad clips if they are twist-
ed or worn.3) Check the disc rotor, and correct or replace if it is
damaged or worn.
4) Remove the caliper body. Disc Brake Assembly.> Brake Assembly.>
5) Tighten the wheel nuts to secure disk rotor.
6) Set a dial gauge at a point less than 10 mm (0.39
in) from outer periphery of rotor, and then measure
the disk rotor runout.
Disc rotor runout limit:
Front: 0.075 mm (0.0030 in)
Rear: 0.070 mm (0.0028 in)
(A) Inspection hole
Pad thickness including back metal mm (in)
Front Rear
Standard 17 (0.67) 14 (0.55)
Wear limit 7.5 (0.295) 6.5 (0.256)
(A) Thickness of pad
(B) Back metal
(C) Lining
PM-00049
(A)
PM-00050
(A)
(C)
(B)
Brake disc thickness mm (in)
Front Rear
Standard 24 (0.94) 10 (0.39)
Wear limit 22 (0.87) 8.5 (0.335)
PM-00051

PM-34
PERIODIC MAINTENANCE SERVICE
Brake Linings and Drums
21.Brake Linings and Drums
A: INSPECTION
1. REAR DRUM BRAKE
1) Remove the brake drum, and check that there is
no fluid leakage from wheel cylinder.
If there is fluid leakage from wheel cylinder, inspect
the wheel cylinder, and then repair or replace it.
2) Inspect the brake shoes for damage or deformi-
ties and check brake linings for wear.
CAUTION:
 Always replace both leading and trailing
brake shoes for the right and left wheels at the
same time.
 When either the right and left brake assembly
is replaced, always replace the leading shoe
and trailing shoe of the other.
Thickness of lining (except back metal)
Standard value: 4.1 mm (0.161 in)
Service limit: 1.5 mm (0.059 in)
3) Check the brake drum for wear, dents or other
damage.
If the inside surface of brake drum is streaked, cor-
rect the surface with emery cloth (#200 or more). If
it is unevenly worn, tapered or the outside surface
of brake drum is damaged, correct or replace it.
Brake drum inner diameter
Standard value: 228.6 mm (9.000 in)
Service limit: 230.6 mm (9.079 in)If deformation or wear of back plate, shoe, etc. is
noticeable, replace the affected parts.
2. PARKING BRAKE (REAR DISC BRAKE)
Inspect the brake linings and the disk rotor inside of
both sides of the rear brake at the same time by re-
moving the disk rotor.
1) Inspect the brake shoes for damage or deforma-
tion and check brake linings for wear.
CAUTION:
Always replace both primary and secondary
brake shoes for the right and left wheels at the
same time.
Brake lining thickness (excluding back metal)
Standard value: 3.2 mm (0.126 in)
Wear limit: 1.5 mm (0.059 in)
(A) Rotational direction of drum (Forward)
(B) Wheel cylinder
(C) Upper shoe return spring
(D) Adjusting lever
(E) Trailing shoe
(F) Lower shoe return spring
(G) Leading shoe
PM-00052
(B)
(C)
(D)
(E)
(F) (G) (A)
(A) Inside diameter
(A) Forward
(B) Brake shoe (Primary side)
(C) Brake shoe (Secondary side)
PM-00053(A)
PM-00054
(B)
(C) (A)

PM-36
PERIODIC MAINTENANCE SERVICE
Suspension
22.Suspension
A: INSPECTION
1. SUSPENSION BALL JOINT
1) Jack-up the vehicle until front wheels are off
ground.
2) Grasp the bottom of tire and move it in and out.
If relative movement (B) is observed between the
brake disc cover (A) and end of transverse link (D),
ball joint (C) may be excessively worn.
3) Grasp the end of transverse link (C) and move it
up and down. Relative movement (A) between the
housing (D) and transverse link boss indicates ball
joint (B) may be excessively worn.
4) If relative movement is observed in the immedi-
ately preceding two steps, remove and inspect the
ball joint. If free play exceeds standard, replace the
ball joint.
5) Damage of dust seal
Visually inspect the ball joint dust seal. If it is dam-
aged, remove the transverse link. Front Transverse Link.> And measure free play of
ball joint.
(1) When looseness exceeds standard value,
replace the ball joint.
(2) If the dust seal is damaged, replace with the
new ball joint.
NOTE:
When the transverse link ball joint has been re-
moved or replaced, check the toe-in of front wheel. If the front wheel toe-in is not at specified value, ad-
just the toe-in.
2. TRANSVERSE LINK’S REAR BUSHING
Check oil leaks at around liquid-filled bushing. If oil
leaks, replace the bushing.
3. WHEEL ARCH HEIGHT
1) Unload cargoes and set the vehicle in curb
weight (empty) condition.
2) Then, check the wheel arch height of front and
rear suspensions to ensure that they are within
specified values.
3) When the wheel arch height is out of standard,
visually inspect the following components and re-
place deformed parts.
 Suspension components [Front strut assembly
and rear strut assembly]
 Parts connecting between suspension and body.
4) When no components are deformed, adjust the
wheel arch height by replacing coil spring in the
suspension which wheel arch height is out of stan-
dard. RS-8, Wheel Alignment.>
PM-00057
(A)
(B)
(C) (D)
PM-00058
(A)
(B) (C)(D)
(A) Dust seal
(A) Rear bushing
(B) Transverse link
PM-00059
(A)
PM-00060
(A)
(B)

PM-37
PERIODIC MAINTENANCE SERVICE
Suspension
4. WHEEL ALIGNMENT OF FRONT SUS-
PENSION
1) Check the alignment of front suspension to en-
sure that following items conform to standard val-
ues.
 Toe-in
 Camber angle
 Caster angle
 Steering angle

2) When the caster angle does not conform to ref-
erence, visually inspect the following components
and replace deformed parts.
 Suspension components [Strut assembly, cross-
member, transverse link, etc.]
 Body parts to which suspensions are installed.
3) When the toe-in and camber are out of standard
value, adjust them so that they conform to respec-
tive service standard. WHEEL TOE-IN, INSPECTION, Wheel Align-
ment.> Wheel Alignment.>
4) When the right-and-left turning angles of tire are
out of standard, adjust to standard value. FS-10, STEERING ANGLE, INSPECTION, Wheel
Alignment.>
5. WHEEL ALIGNMENT OF REAR SUS-
PENSION
1) Check the alignment of rear suspension to en-
sure that following items are within standard val-
ues.
 Toe-in
 Camber angle
 Thrust angle

2) When the camber angle does not conform to ref-
erence, visually inspect parts listed below. If defor-
mation is observed, replace the damaged parts.
 Suspension components [Shock absorber, front
lateral links, rear lateral links, trailing link, etc.]
 Body parts to which suspensions are installed.
3) When the toe-in and thrust angle are out of stan-
dard value, adjust them so that they conform to re-
spective service standard. WHEEL TOE-IN, INSPECTION, Wheel Align-
ment.> SPECTION, Wheel Alignment.>
6. OIL LEAKAGE OF STRUT
Visually inspect the front strut and rear strut for oil
leakage as instructed. If oil leakage reaches under
spring seat lower portion, replace the front strut and
rear strut.
7. TIGHTNESS OF BOLTS AND NUTS
Check the bolts and nuts shown in the figure for
looseness. Retighten the bolts and nuts to speci-
fied torque. If the self-lock nuts and bolts are re-
moved, replace them with new ones.
Front suspension: tion.>
Rear suspension: tion.>
8. DAMAGE TO SUSPENSION PARTS
Check the following parts and the fastening portion
of the vehicle body for deformation or excessive
rusting which impairs the suspension. Remove the
contaminations on spring seat lower portion with
care because dirt, sand, etc. tend to accumulate on
it. If necessary, replace the damaged parts with
new ones. If minor rust formation, pitting, etc. are
noted, remove the rust and apply remedial anti-cor-
rosion measures.
 Front suspension
 Transverse link
 Crossmember
Strut
 Rear suspension
 Crossmember
 Lateral links
 Trailing link
Strut
 In the district where salt is sprayed to melt snow
on a road in winter, check suspension parts for
damage caused by rust every 12 months after
lapse of 60 months. Take rust prevention measure
as required.

PM-38
PERIODIC MAINTENANCE SERVICE
Wheel Bearing
23.Wheel Bearing
A: INSPECTION
1. FRONT WHEEL BEARING
NOTE:
Inspect the condition of front wheel bearing grease.
1) Lift-up the front of vehicle.
2) While holding the front wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts and remove front wheel.
4) If bearing free play exists in step 2) above, at-
tach a dial gauge to the hub and measure axial dis-
placement in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the bolts and self-locking nuts, and ex-
tract transverse link from front crossmember.
6) Remove the AARi of front drive shaft from trans-
mission.
7) While supporting the front drive shaft horizontal-
ly with one hand, turn the hub with the other to
check for noise or binding.
If the hub is noisy or binds, disassemble the front
axle and check condition of oil seals, bearing, etc.
2. REAR WHEEL BEARING
1) Lift-up the rear of vehicle.
2) While holding the rear wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts and remove rear wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to the hub assembly and mea-
sure axial displacement in axial direction.Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the DOJ of rear drive shaft from rear dif-
ferential.
6) While supporting the rear drive shaft horizontally
with one hand, turn the hub assembly with the other
to check for noise or binding.
If the hub assembly is noisy or binds, disassemble
the rear axle and check condition of oil seals, bear-
ings, etc.
(A) Inner oil seal
(B) Snap ring
(C) Bearing
(D) Housing
(E) Outer oil seal
(F) Hub bolt
(G) Hub
PM-00061
(A)
(B)
(C)
(D)
(E)(G) (F)
(A) Inner oil seal
(B) Rear housing
(C) Bearing
(D) Snap ring
(E) Outer oil seal
(F) Tone wheel
(G) Hub bolt
(H) Hub
(I) Socket bolt
PM-00062
(A)
(B)
(C)
(D)
(E)(G)
(H)
( I ) (F)

PM-40
PERIODIC MAINTENANCE SERVICE
Tire Rotation
25.Tire Rotation
A: INSPECTION
1) Replace the tire if the tread depth is less than 1.6
mm (0.063 in) or if wear indicators appear across
the tire tread.
CAUTION:
It is recommended that both right and left tires
are replace as a set.
2) Adjust the wheel alignment if abnormally uneven
tire wear is found.
3) Also, rotate the tires between the front and rear
tires as illustrated every 10,000 km (6,200 miles)
running, in order to ensure uniform tire wear.
(A) New tread
(B) Worn tread
(C) Tread wear indicator
PM-00079
PM-00080
(A) (B)
(C)

PM-41
PERIODIC MAINTENANCE SERVICE
Steering System (Power Steering)
26.Steering System (Power
Steering)
A: INSPECTION
1. STEERING WHEEL
1) Set the steering wheel in a straight-ahead posi-
tion, and check the wheel spokes to make sure
they are correctly set in their specified positions.
2) Lightly turn the steering wheel to the right and
left to determine the point where front wheels start
to move.
Measure the distance of the movement of steering
wheel at the outer periphery of wheel.
Steering wheel free play:
0 — 17 mm (0 — 0.67 in)
Move the steering wheel vertically toward the shaft
to ascertain if there is play in the direction.
Maximum permissible play:
0.5 mm (0.020 in)
3) Drive the vehicle and check the following items.
(1) Steering force:
The effort required for steering should be
smooth and even at all points, and should not
vary.
(2) Pull to one side:
Steering wheel should not be pulled to either
side while driving on a level surface.
(3) Wheel runout:
Steering wheel should not be runout.
(4) Return factor:
Steering wheel should return to its original posi-
tion after it has been turned and then released.
2. STEERING SHAFT JOINT
When the steering wheel free play is excessive,
disconnect the universal joint of steering shaft and
check it for any play and yawing torque (at the point
of the crossing direction). Also inspect for any dam-
age to sealing or worn serrations. If the joint is
loose, retighten the mounting bolts to the specified
torque.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)
3. GEARBOX
1) With wheels placed in the direction of straight
ahead, turn the steering wheel 90° in both the right
and left directions.
While the steering wheel is being rotated, check for
looseness in gearbox.
Tightening torque:
59 N·m (6.0 kgf-m, 43.4 ft-lb)
2) Check the boot for damage, cracks or deteriora-
tion.
3) With the vehicle on a level surface, quickly turn
the steering wheel to the right and left.
While the steering wheel is being rotated, check the
gear backlash. If any unusual noise is noticed, ad-
just the gear backlash in the following manner.
(1) Tighten the adjusting screw to 7.4 N·m (0.75
kgf-m, 5.4 ft-lb) and then loosen. Repeat this op-
eration twice.
(A) Steering wheel free play
PM-00065
(A)
SUBARUSRS AIRBAG
(A) Boot
(B) Gear box mounting bolt
PM-00066
PM-00067
(A)
(B)