SUBARU LEGACY 1996 Service Repair Manual

G4M0425
3) Use care when placing brake booster on the floor.
CAUTION:
If external force is applied from above when brake
booster is placed in this position, the resin portion as
indicated by“P”, may be damaged.
G4M0424
4) Do not change the push rod length. If it has been
changed, reset the projected length“L”to the standard
length.
Standard:
L = 10 mm (0.39 in)
55
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).
56
4-4SERVICE PROCEDURE
7. Brake Hose

G4M0428
8. Hill Holder
A: REMOVAL
1) Drain brake fluid from reservoir of master cylinder.
2) Remove adjusting nut and cable clamp, and disconnect
PHV cable from cable bracket on engine.
3) Detach PHV cable from clips.
4) Remove cable clamp, and disconnect PHV cable from
PHV stay.
CAUTION:
Carefully protect boots and inner cable from damage
when disconnecting PHV cable.
5) Disconnect brake pipes from PHV.
CAUTION:

Pay attention not to drop brake fluid onto body
painting since it may dissolve paint.

Pay attention not to damage hexagonal head of flare
nut by using pipe wrench without fail.
6) Detach PHV along with support from side frame.
CAUTION:
Exercise utmost care to prevent foreign matter from
entering into PHV when removing it.
B: INSPECTION
Check up removed parts as follows, and replace defective
ones.
1) Check if boots of PHV cable are damaged or degraded,
and if inner cable is damaged or corroded.
2) Check if return spring is worn out, damaged or cor-
roded.
3) Confirm that rolling sound of ball is heard with PHV
inclined and lever rotates smoothly.
CAUTION:
Never disassemble PHV. Replace entire PHV assembly
if necessary.
57
4-4SERVICE PROCEDURE
8. Hill Holder

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.
58
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

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

10. Parking Brake Cable
B4M0070A
1Parking brake lever

2Parking brake switch

3Lock nut

4Adjusting nut

5Equalizer

6Bracket
7Clamp

8Parking brake cable RH

9Cable guide

10Clamp
(Rear disc brake model only)

11Parking brake cable LH
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5.9±1.5 (0.60±0.15, 4.3±1.1)
T2: 18±5 (1.8±0.5, 13.0±3.6)
T3: 32±10 (3.3±1.0, 24±7)
A: REPLACEMENT
1) Lift-up vehicle.
2) Remove rear wheels.
3) Remove rear cushion.
4) Remove console box from front floor.
5) Loosen parking cable adjusting nut.
60
4-4SERVICE PROCEDURE
10. Parking Brake Cable

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].>
61
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.
62
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) 4-4 [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.
63
4-4SERVICE PROCEDURE
11. Air Bleeding (Without TCS model)