SUBARU LEGACY 1995 Service Repair Manual

B4M0077A
6) Roll up floor mat and remove clamps.
B4M0078A
7) Remove inner cable end from equalizer.
8) Pull out parking brake cable from parking brake assem-
bly.
9) Pull out clamp from parking brake assembly.
10) Remove bolt and bracket from trailing link bracket.
G4M0433
11) Remove bolt and clamp from rear floor.
12) Detach grommet from rear floor.
13) Remove cable assembly from cabin by forcibly pulling
it backward.
14) Detach parking brake cable from cable guide at rear
trailing link.
15) Install (new) parking brake assembly in the reverse
order of removal.
NOTE:

Be sure to pass cable through cable guide inside the
tunnel.

Be sure to adjust the lever stroke. [W4D1].>
54
4-4SERVICE PROCEDURE
10. Parking Brake Cable

11. Air Bleeding (Without TCS model)
A: GENERAL RULES FOR EFFECTIVE
BLEEDING
1) Start with the brakes (wheels) connecting to the sec-
ondary chamber of the master cylinder.
2) The time interval between two brake pedal operations
(from the time when the pedal is released to the time when
it is depressed another time) shall be approximately 3 sec-
onds.
3) The air bleeder on each brake shall be released for 1
to 2 seconds.
B: BLEEDING PROCEDURE
CAUTION:

The FMVSS No. 116, fresh DOT3 or 4 brake fluid
must be used.

Cover bleeder with waste cloth, when loosening it,
to prevent brake fluid from being splashed over sur-
rounding parts.

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

Be careful not to allow dirt or dust to get into the
reservoir tank.
NOTE:

During bleeding operation, keep the brake reserve tank
filled with brake fluid to eliminate entry of air.

Brake pedal operating must be very slow.

For convenience and safety, it is advisable to have two
man working.
G4M0434
G4M0435
1) Make sure that there is no leak from joints and connec-
tions of the brake system.
2) Fit one end of vinyl tube into the air bleeder and put the
other end into a brake fluid container.
3) Slowly depress the brake pedal and keep it depressed.
Then, open the air bleeder to discharge air together with
the fluid.
Release air bleeder for 1 to 2 seconds.
Next, with the bleeder closed, slowly release the brake
pedal.
Repeat these steps until there are no more air bubbles in
the vinyl tube.
Allow 3 to 4 seconds between two brake pedal operations.
CAUTION:
Cover bleeder with waste cloth, when loosening it, to
prevent brake fluid from being splashed over sur-
rounding parts.
NOTE:
Brake pedal operating must be very slow.
4) Tighten air bleeder securely when no air bubbles are
visible.
55
4-4SERVICE PROCEDURE
11. Air Bleeding (Without TCS model)

Air bleeder tightening torque:
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
5) Perform these steps for the brakes connecting to the
secondary chamber of master cylinder, first, and then for
the ones connecting to primary chamber. With all proce-
dures completed, fully depress the brake pedal and keep
it in that position for approximately 20 seconds to make
sure that there is no leak evident in the entire system.
G4M0436
6) Perform sequence control. (With ABS model) [W15C1].>
7) Check the pedal stroke.
While the engine is idling, depress the brake pedal with a
490 N (50 kg, 110 lb) load and measure the distance
between the brake pedal and steering wheel. With the
brake pedal released, measure the distance between the
pedal and steering wheel again. The difference between
the two measurements must be more than specified.
Specified pedal stroke:
Without ABS
90 mm (3.54 in)
With ABS
95 mm (3.74 in)
When depressing brake pedal with a 490 N (50 kg,
110 lb) load.
(1) Models without ABS
If the distance is more than specifications, there is a
possibility that air is in the brake line. Bleed air from the
brake line.
(2) Models with ABS
If the distance is more than specifications, there is a
possibility air is in the inside of the hydraulic unit.
Therefore, air must be bled from the inside of the
hydraulic unit to the brake pipes in accordance with the
bleeding sequence control.
8) Add brake fluid to the required level (MAX. level) of
reserve tank.
9) As a final step, test run the vehicle at low speed and
apply brakes relatively hard 2 to 3 times to ensure that
brakes provide normal braking action on all four wheels
without dragging and uneven braking.
56
4-4SERVICE PROCEDURE
11. Air Bleeding (Without TCS model)

12. Brake Fluid Replacement
NOTE:
To always maintain the brake fluid characteristics, replace
the brake fluid according to maintenance schedule or ear-
lier than that when used in severe condition.
A: REPLACEMENT
CAUTION:

The FMVSS No. 116, fresh DOT3 or 4 brake fluid
must be used.

Cover bleeder with waste cloth, when loosening it,
to prevent brake fluid from being splashed over sur-
rounding parts.

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

Be careful not to allow dirt or dust to get into the
reservoir tank.
NOTE:

During bleeding operation, keep the brake reserve tank
filled with brake fluid to eliminate entry of air.

Brake pedal operating must be very slow.

For convenience and safety, it is advisable to have two
man working.

The amount of brake fluid required is approximately 500
m
(16.9 US fl oz, 17.6 Imp fl oz) for total brake system.
1) Either jack-up vehicle and place a safety stand under it,
or lift-up vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from reserve tank with syringe.
4) Refill reservoir tank with recommended brake fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
57
4-4SERVICE PROCEDURE
12. Brake Fluid Replacement

G4M0434
G4M0438
G4M0435
5) Install one end of a vinyl tube onto the air bleeder of and
insert the other end of the tube into a container to collect
the brake fluid.
6) Instruct your co-worker to depress the brake pedal
slowly two or three times and then hold it depressed.
7) Loosen bleeder screw approximately 1/4 turn until a
small amount of brake fluid drains into container, and then
quickly tighten screw.
8) Repeat steps 6) and 7) above until there are no air
bubbles in drained brake fluid and new fluid flows through
vinyl tube.
CAUTION:
Add brake fluid as necessary while performing the air
bleed operation, in order to prevent the tank from run-
ning short of brake fluid.
9) After completing the bleeding operation, hold brake
pedal depressed and tighten screw and install bleeder cap.
Tightening torque (Bleeder screw):
8±1 N⋅m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
10) Bleed air from each wheel cylinder using the same
procedures as described in steps 6) through 7) above.
11) Depress brake pedal with a force of approximately 294
N (30 kg, 66 lb) and hold it there for approximately 20 sec-
onds. At this time check pedal to see if it shows any
unusual movement.
Visually inspect bleeder screws and brake pipe joints to
make sure that there is no fluid leakage.
12) Install wheels, and drive vehicle for a short distance
between 2 to 3 km (1 to 2 miles) to make sure that brakes
are operating properly.
58
4-4SERVICE PROCEDURE
12. Brake Fluid Replacement

G4M0440
13. Proportioning Valve
G4M0668
G4M0915
A: INSPECTION
1) Install the oil pressure gauges to measure the master
cylinder fluid pressure (front wheel brake fluid pressure)
and rear wheel cylinder fluid pressure.
2) Bleed air from the oil pressure gauges.
3) Check the master cylinder fluid pressure and rear wheel
cylinder fluid pressure.
The standard values are shown in Figure.
4) For the oil pressure in case of split point, refer to A:
SPECIFICATIONS [S0A0].
B: REMOVAL
1) Remove brake pipe from proportioning valve at four
places.
2) Remove proportioning valve from its bracket.
CAUTION:
Do not disassemble or adjust the proportioning valve.
(The proportioning valve must be replaced as an
assembly.)
C: INSTALLATION
1) Install proportioning valve to bracket.
2) Connect brake pipes correctly to proportioning valve.
3) Bleed air, then check each joint of brake pipe for oil
leaks.
Tightening torque:
Proportioning valve to brake pipe flare nut:
15
+3
2N⋅m (1.5+0.3
0.2kg-m, 10.8+2.2
1.4ft-lb)
Proportioning valve to bracket:
18±5 N⋅m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
59
4-4SERVICE PROCEDURE
13. Proportioning Valve

14. ABS Sensor
A: REMOVAL
1. FRONT ABS SENSOR
1) Disconnect front ABS sensor connector located in
engine compartment.
B4M0079A
2) Remove bolts which secure sensor harness to strut.
G4M0451
3) Remove bolts which secure sensor harness to body.
G4M0443
4) Remove bolts which secure front ABS sensor to
housing, and remove front ABS sensor.
CAUTION:

Be careful not to damage pole piece located at tip of
the sensor and teeth faces during removal.

Do not pull sensor harness during removal.
5) Remove front disc brake caliper and disc rotor from
housing after removing front tire.
6) Remove front drive shaft and housing and hub assem-
bly.
60
4-4SERVICE PROCEDURE
14. ABS Sensor

G4M0444
7) Remove tone wheel while removing hub from housing
and hub assembly.
CAUTION:
Be careful not to damage teeth faces of tone wheel
during removal.
2. REAR ABS SENSOR
1) Remove rear seat and disconnect rear ABS sensor con-
nector.
2) Remove rear sensor harness bracket from rear trailing
link and bracket.
G4M0445
3) Remove rear ABS sensor from rear back plate.
4) Remove rear tone wheel while removing hub from
housing and hub assembly.
CAUTION:

Be careful not to damage pole piece located at tip of
the sensor and teeth faces during removal.

Do not pull sensor harness during removal.
B: INSPECTION
1. ABS SENSOR
1) Check pole piece of ABS sensor for foreign particles or
damage. If necessary, clean pole piece or replace ABS
sensor.
61
4-4SERVICE PROCEDURE
14. ABS Sensor

B4M0248
2) Measure ABS sensor resistance.
ABS sensor Terminal No. Standard
Front - LH 1 and 2
1.0±0.2 kΩ Front - RH 1 and 2
Rear - LH 1 and 2
Rear - RH 1 and 2
CAUTION:
If resistance is outside the standard value, replace
ABS sensor with new one.
NOTE:
Check ABS sensor cable for discontinuity. If necessary,
replace with a new one.
G4M0448
2. TONE WHEEL
1) Check tone wheel’s teeth (44 pieces) for cracks or
dents. If necessary, replace tone wheel with a new one.
2) Clearances (sensor gaps) should be measured one by
one to ensure tone wheel and speed sensor are installed
correctly.
ABS sensor clearance:
Front
0.9—1.4 mm (0.035—0.055 in)
Rear
0.7—1.2 mm (0.028—0.047 in)
NOTE:

If clearance is narrow, adjust by using spacer (Part No.
26755AA000).

If clearance is wide, check the outputted voltage then
replace ABS sensor or tone wheel if the outputted voltage
is outside the specification.
62
4-4SERVICE PROCEDURE
14. ABS Sensor

B4M0118B
3. OUTPUT VOLTAGE
Output voltage can be checked by the following method.
Install resistor and condenser, then rotate wheel about 2.75
km/h (2 MPH) or equivalent.
NOTE:
Regarding terminal No., please refer to item 1. ABS SEN-
SOR.
C: INSTALLATION
1. FRONT ABS SENSOR
1) Install tone wheel on hub, then install housing on hub
assembly.
G4M0443
2) Temporarily install front ABS sensor on housing.
CAUTION:
Be careful not to strike ABS sensor’s pole piece and
tone wheel’s teeth against adjacent metal parts during
installation.
3) Install front drive shaft to hub spline. [W1E0].>
63
4-4SERVICE PROCEDURE
14. ABS Sensor