Strut SUBARU LEGACY 1996 Service Owner's Guide

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

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.
44
4-4SERVICE PROCEDURE
4. Parking Brake (Rear Disc Brake)

G4M0413
10) Remove parking cable from parking lever.
11) Using a standard screwdriver, raise retainer. Remove
parking lever and washer from brake shoe.
B: INSPECTION
1) Measure brake disc inside diameter. If the disc is scored
or worn, replace the brake disc.
Disc inside diameter:
Standard
170 mm (6.69 in)
Service limit
171 mm (6.73 in)
2) Measure the lining thickness. If it exceeds the limit,
replace shoe assembly.
Lining thickness:
Standard
3.2 mm (0.126 in)
Service limit
1.5 mm (0.059 in)
CAUTION:
Replace the brake shoes on the right and left brake
assembly at the same time.
C: INSTALLATION
CAUTION:
Be sure lining surface is free from oil contamination.
Brake grease:
Dow Corning Molykote No 7439 (Part No.
725191460)
1) Apply brake grease to the following places.

Six contact surfaces of shoe rim and back plate
packing

Contact surface of shoe wave and anchor pin

Contact surface of lever and strut

Contact surface of shoe wave and adjuster assem-
bly

Contact surface of shoe wave and strut

Contact surface of lever and shoe wave
45
4-4SERVICE PROCEDURE
4. Parking Brake (Rear Disc Brake)

2) Installation is in reverse order of removal.
CAUTION:

Use new retainers and clinch them when installing
brake shoes to levers.

Ensure that parking lever moves smoothly.

Do not confuse left parking lever with right one.

Do not confuse left strut with right one.
G4M0414
NOTE:
Ensure that adjuster assembly is securely installed with
screw in the left side, facing vehicle front.
G4M0415
NOTE:
Ensure that shoe return spring is installed as shown in
Figure.
3) Adjust parking brakes.
CAUTION:
After replacing parking brake lining, be sure to drive
vehicle for“break-in”purposes.
(1) Drive the vehicle about 35 km/h (22 MPH).
(2) With the parking brake release button pushed in,
pull the parking brake lever gently, pulling with a force
of approximately 147 N (15 kg, 33 lb).
(3) Drive the vehicle for about 200 m (0.12 mile) in this
condition.
(4) Wait 5 to 10 minutes for the parking brake to cool
down. Repeat this procedure once more.
(5) After breaking-in, re-adjust parking brakes.
46
4-4SERVICE PROCEDURE
4. Parking Brake (Rear Disc Brake)

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

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.
67
4-4SERVICE PROCEDURE
14. ABS Sensor

G4M0451
4) Install front ABS sensor on strut and wheel apron
bracket.
Tightening torque:
32±10 N⋅m (3.3±1.0 kg-m, 24±7 ft-lb)
5) Place a thickness gauge between ABS sensor’s pole
piece and tone wheel’s tooth face. After standard clearance
is obtained over the entire perimeter, tighten ABS sensor
on housing to specified torque.
ABS sensor standard clearance:
0.9—1.4 mm (0.035—0.055 in)
Tightening torque:
32±10 N⋅m (3.3±1.0 kg-m, 24±7 ft-lb)
CAUTION:
Check the marks on the harness to make sure that no
distortion exists. (RH: white, LH: yellow)
NOTE:
If the clearance is outside specifications, readjust.
2. REAR ABS SENSOR
1) Install rear tone wheel on hub, then rear housing on
hub.
G4M0445
2) Temporarily install rear ABS sensor on back plate.
CAUTION:
Be careful not to strike ABS sensor’s pole piece and
tone wheel’s teeth against adjacent metal parts during
installation.
71
4-4SERVICE PROCEDURE
14. ABS Sensor

1. ENGINE COMPARTMENT AND ROOM
B5M0187A
0Cowl panel weather attaching hole 6 mm (0.24 in) dia.

1Hood hinge front attaching hole M8

2Strut mount attaching hole (Front center) 9.5 mm (0.374 in)
dia.

3Front fender attaching hole (Tip) M6

4Rear upper surface of front side frame 12 mm (0.47 in) dia.

5Middle upper surface of front side frame 20 mm (0.79 in) dia.

6Front side frame front upper surface 14 x 16 mm (0.55 x 0.63
in) dia. oblong hole

7Side frame of front side frame 12 mm (0.47 in) dia.

8Headlight attaching hole at radiator side panel 6.2x9mm
(0.244 x 0.35 in) dia.

9Radiator panel side (LWR) gauge hole 23 mm (0.91 in) dia.

23Rear strut mount attaching hole (Side) 10 mm (0.39 in) dia.

24Rear strut mount attaching hole (Center) 12 mm (0.47 in) dia.

25Radiator panel (UPR) middle hole 6 mm (0.24 in) dia.

26Front fender attaching hole at radiator panel side M6

27Front fender attaching hole at front pillar lower portion M6

28Hinge middle hole at front pillar center 10 mm (0.39 in) dia.

29Front fender attaching hole at front pillar center portion M6

30Retainer attaching square hole at front pillar7x7mm(0.28
x 0.28 in)
31Retainer attaching hole at center pillar (Front) 3.5 mm (0.138
in) dia.

32Retainer attaching hole at center pillar (Rear) 3.5 mm (0.138
in) dia.

33Lower side of rear door hinge M8

34Center pillar (LWR) gauge hole 27 mm (1.06 in) dia.

35Rear quarter outer corner patch attaching hole 5.2 mm (0.205
in) dia.

39Front rail center notch

40Front glass upper locating notch RH: 6.5 mm (0.256 in) dia.,
LH: 6.5 x 10 mm (0.256 x 0.39 in) dia. oblong hole

41Stud bolt lower locating notch

48Front center of rear floor pan 8 mm (0.31 in) dia.

51Front upper pillar (Inner) 7 mm (0.28 in) dia.

52Front seat belt adjust plate attaching hole 12 mm (0.47 in)
dia.

53Rear door hinge middle hole 10 mm (0.39 in) dia.

54Rear floor, near door 8 mm (0.31 in) dia.

55Trim upper attaching hole at 6 light 8 mm (0.31 in) dia.

56Trim lower attaching hole at 6 light 8 mm (0.31 in) dia.

58Rear floor, near floor strut 15 x 20 mm (0.59 x 0.79 in) dia.
oblong hole
3
5-1SERVICE DATA
2. Body Datum Points

5. Inner Trim
B5M0036B
1Front pillar upper trim

2Center pillar upper trim

3Side sill rear upper cover

4Side sill rear lower cover

5Side sill front lower cover

6Front pillar lower trim

7Center pillar lower trim
8Rear quarter upper front trim

9Rear quarter upper rear trim

10Rear rail trim

11Edge rear trim

12Rear quarter pillar lower trim

13Cap strut

14Lid pocket
15Rear pillar upper

16Rear upper bulk

17Trunk side trim

18Trunk rear trim

19Rear side bulk trim

20Rear pillar lower trim

21Lamp cover
7
5-3COMPONENT PARTS
5. Inner Trim

G5M0358
4. Rear Seat Belt
A: REMOVAL AND INSTALLATION
1. SEDAN MODEL
1) Remove rear cushion from vehicle.
2) Remove rear backrest from vehicle.
3) Remove rear pillar upper trim.
4) Remove outer anchor bolts.
B5M0040
5) Remove ELR.
G5M0360
6) Remove anchor bolt of outer belt and then remove outer
belt assembly.
7) Remove inner belt.
8) Installation is in the reverse order of removal.
B5M0041
2. WAGON MODEL
1) Raise rear cushion.
2) Remove shoulder anchor bolt.
3) Remove cap strut.
4) Remove rear quarter upper front trim.
G5M0362
5) Remove ELR assembly.
CAUTION:
Remove outer seat belt and center seat belt in similar
manner used to remove those from Sedan model.
12
5-3SERVICE PROCEDURE
4. Rear Seat Belt