SUBARU LEGACY 1996 Service Repair Manual

3. 2500 cc AND OUTBACK (STEP ROOF) MODEL
Model Sedan Wagon
Engine (cc) 2500 2200 2500
Driving system AWD
GT LSi GT LSi OUTBACK* OUTBACK*
Front
brakeType Disc (Floating type, ventilated)
Effective disc diameter
mm (in)228 (8.98)
Disc thickness x Outer
diameter
mm (in)24 x 277 (0.94 x 10.91)
Effective cylinder
diameter
mm (in)42.8 (1.687) x 2
Pad dimensions
(length x width x
thickness)
mm (in)112.3 x 50.0 x 11.0 (4.42 x 1.969 x 0.433)
Clearance adjustment Automatic adjustment
Rear
brakeType Disc (Floating type)
Effective disc diameter
mm (in)230 (9.06)
Disc thickness x Outer
diameter
mm (in)10 x 266 (0.39 x 10.47)
Effective cylinder
diameter
mm (in)38.1 (1.500)
Pad dimensions
(length x width x
thickness)
mm (in)92.4 x 33.7 x 10.0 (3.638 x 1.327 x 0.394)
Clearance adjustment Automatic adjustment
*: Step roof model
6
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

Model Sedan Wagon
Engine (cc) 2500 2200 2500
Driving system AWD
GT LSi GT LSi OUTBACK* OUTBACK*
Hill holder————STD—
Parking
brakeType Mechanical on rear brakes, drum in disc
Effective drum diameter
mm (in)170 (6.69)
Lining dimensions
(length x width x
thickness)
mm (in)162.6 x 30.0 x 3.2 (6.40 x 1.181 x 0.126)
Clearance adjustment Manual adjustment
Master
cylinderType Tandem
Effective diameter
mm (in)26.99 (1-1/16)
Reservoir type Sealed type
Brake fluid reservoir
capacity
cm
3(cu in)190 (11.59)
Brake
boosterType Vacuum suspended
Effective diameter
mm (in)205 + 230 (8.07 + 9.06)
Propor-
tioning
valveSplit point
kPa (kg/cm
2, psi)3,678 (37.5, 533)
Reducing ratio 0.3
Brake line Dual circuit system
ABSSTD
*: Step roof model
7
4-4SPECIFICATIONS AND SERVICE DATA
1. Brakes

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

1. Front Disc Brake
1. EXCEPT 2500 cc AND OUTBACK (STEP ROOF)
MODEL
B4M0065A
1Air bleeder screw

2Guide pin

3Guide pin boot

4Piston

5Piston seal

6Piston boot

7Lock pin boot

8Lock pin sleeve

9Caliper body
10Lock pin

11Housing

12Support

13Pad clip

14Outer shim

15Outer pad

16Inner pad

17Inner shim

18Shim
19Disc rotor

20Disc cover
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 8±1 (0.8±0.1, 5.8±0.7)
T2: 18±5 (1.8±0.5, 13.0±3.6)
T3: 39±5 (4±0.5, 28.9±3.6)
T4: 78±10 (8.0±1.0, 58±7)
9
4-4COMPONENT PARTS
1. Front Disc Brake

2. 2500 cc AND OUTBACK (STEP ROOF) MODEL
G4M0990
1Lock pin

2Lock pin sleeve

3Lock pin boot

4Caliper body

5Air bleeder screw

6Guide pin

7Guide pin boot

8Piston seal

9Piston
10Piston boot

11Boot ring

12Support

13Pad clip

14Outer shim

15Pad (Outside)

16Pad (Inside)

17Inner shim

18Shim
19Disc rotor

20Disc cover
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 8±1 (0.8±0.1, 5.8±0.7)
T2: 18±5 (1.8±0.5, 13.0±3.6)
T3: 36±5 (3.7±0.5, 26.8±3.6)
T4: 49±5 (5.0±0.5, 36.2±3.6)
T5: 78±10 (8.0±1.0, 58±7)
10
4-4COMPONENT PARTS
1. Front Disc Brake

2. Rear Disc Brake
B4M0066A
1Lock pin

2Lock pin sleeve

3Lock pin boot

4Air bleeder screw

5Caliper body

6Guide pin

7Guide pin boot

8Piston seal

9Piston

10Piston boot

11Boot ring

12Support

13Shim

14Inner shim

15Inner pad
16Pad clip

17Outer pad

18Outer shim

19Shoe hold-down pin

20Cover

21Back plate

22Retainer

23Spring washer

24Parking brake lever

25Parking brake shoe
(Secondary)

26Parking brake shoe
(Primary)

27Adjusting spring

28Strut
29Strut shoe spring

30Shoe guide plate

31Secondary shoe return spring

32Primary shoe return spring

33Adjuster

34Shoe hold-down cup

35Shoe hold-down spring

36Disc rotor
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 8±1 (0.8±0.1, 5.8±0.7)
T2: 20±4 (2.0±0.4, 14.5±2.9)
T3: 26±5 (2.7±0.5, 19.5±3.6)
T4: 52±6 (5.3±0.6, 38.3±4.3)
11
4-4COMPONENT PARTS
2. Rear Disc Brake

3. Rear Drum Brake
G4M0910
1Air bleeder cap

2Air bleeder screw

3Boot

4Piston

5Cup

6Spring

7Wheel cylinder body

8Pin

9Plug

10Back plate
11Upper shoe return spring

12Retainer

13Washer

14Parking brake lever

15Brake shoe (Trailing)

16Brake shoe (Leading)

17Shoe hold-down spring

18Cup

19Adjusting lever

20Adjuster
21Lower shoe return spring

22Adjusting spring

23Drum

24Plug
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 8±1 (0.8±0.1, 5.8±0.7)
T2: 10±2 (1.0±0.2, 7.2±1.4)
T3: 52±6 (5.3±0.6, 38.3±4.3)
12
4-4COMPONENT PARTS
3. Rear Drum Brake

4. Master Cylinder
1. WITHOUT TCS
B4M0067A
1Cap

2Reserve tank

3Seal

4Cylinder body

5Secondary piston

6Primary piston
7C-ring

8Level indicator ASSY

9Supply valve stopper
(With ABS)

10Gasket (With ABS)

11Reservoir stopper bolt
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 2.2±0.7
(0.225±0.075, 1.6±0.5)
T2: 14±4 (1.4±0.4, 10.1±2.9)
2. WITH TCS
B4M0613A
1Cylinder pin

2Seal

3Filter

4Cylinder body
5Spring

6Secondary piston

7Primary piston

8Stop washer A
9Bush

10Stop washer B

11C-ring
13
4-4COMPONENT PARTS
4. Master Cylinder

3. RHD MODEL
B4M1199A
1Cap

2Filter

3Reservoir tank

4Bracket

5Piston retainer
6Primary piston

7Secondary piston

8Cylinder body

9Seal

10Pin
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 14±4 (1.4±0.4, 10.1±2.9)
14
4-4COMPONENT PARTS
4. Master Cylinder

5. Brake Booster
1. MODELS WITH ABS AND TCS
G4M0355
1Push rod

2Return spring

3Reaction disc

4Key
5Filter

6Silencer

7Operating rod

8Poppet valve
9Valve body

10Plunger valve

11Diaphragm plate

12Valve return spring
2. MODELS WITHOUT ABS AND TCS
G4M0356
1Push rod

2Return spring

3Diaphragm plate

4Reaction disc
5Plunger valve

6Key

7Poppet valve

8Valve return spring
9Operating rod

10Silencer

11Filter

12Valve body
15
4-4COMPONENT PARTS
5. Brake Booster