SUBARU LEGACY 1999 Service Repair Manual

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)
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)
B4M0050A
10. Parking Brake Cable
A: REPLACEMENT
B4M0070B
(1) Parking brake lever
(2) Parking brake switch
(3) Lock nut
(4) Adjusting nut
(5) Equalizer
(6) Bracket(7) Clamp
(8) Parking brake cable RH
(9) Cable guide
(10) Clamp (Rear disc brake model
only)
(11) Parking brake cable LHTightening 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)
46
4-4[W9A0]SERVICE PROCEDURE
9. Parking Brake Lever

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)
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)
B4M0050A
10. Parking Brake Cable
A: REPLACEMENT
B4M0070B
(1) Parking brake lever
(2) Parking brake switch
(3) Lock nut
(4) Adjusting nut
(5) Equalizer
(6) Bracket(7) Clamp
(8) Parking brake cable RH
(9) Cable guide
(10) Clamp (Rear disc brake model
only)
(11) Parking brake cable LHTightening 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)
46
4-4[W9A0]SERVICE PROCEDURE
9. Parking Brake Lever

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.
6) Roll up floor mat and remove clamps.
B4M0077A
7) Remove inner cable end from equalizer.
B4M0078A
8) Pull out parking brake cable from parking brake
assembly.
9) Pull out clamp from parking brake assembly.
10) Remove bolt and bracket from trailing link
bracket.
11) Remove bolt and clamp from rear floor.
G4M0433
12) Detach grommet from rear floor.
13) Remove cable assembly from cabin by forc-
ibly 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:
IBe sure to pass cable through cable guide inside
the tunnel.
IBe sure to adjust the shoe clearance. (Only rear
disc brake model)
16) 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).
17) 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)
B4M0050A
47
[W10A0]4-4SERVICE PROCEDURE
10. Parking Brake Cable

11. Air Bleeding
A: GENERAL RULES FOR
EFFECTIVE BLEEDING
1) Start with the brakes (wheels) connecting to the
secondary 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 seconds.
3) The air bleeder on each brake shall be released
for 1 to 2 seconds.
B: BLEEDING PROCEDURE
CAUTION:
IThe FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
ICover bleeder with waste cloth, when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
IAvoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
IBe careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
IDuring bleeding operation, keep the brake
reserve tank filled with brake fluid to eliminate entry
of air.
IBrake pedal operating must be very slow.
IFor convenience and safety, it is advisable to
have two men working.
1) Make sure that there is no leak from joints and
connections 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.
G4M0434
G4M0435
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 loosen-
ing it, to prevent brake fluid from being
splashed over surrounding parts.
NOTE:
Brake pedal operating must be very slow.
4) Tighten air bleeder securely when no air
bubbles are visible.
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 cham-
ber. With all procedures 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.
6) Perform sequence control. (With ABS model)

48
4-4[W11A0]SERVICE PROCEDURE
11. Air Bleeding

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 measure-
ments must be more than specified.
G4M0436
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 hydrau-
lic 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.
12. Brake Fluid
A: REPLACEMENT
CAUTION:
ITo always maintain the brake fluid
characteristics, replace the brake fluid accord-
ing to maintenance schedule or earlier than
that when used in severe condition.
IThe FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
ICover bleeder with waste cloth, when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
IAvoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
IBe careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
IDuring bleeding operation, keep the brake
reserve tank filled with brake fluid to eliminate entry
of air.
IBrake pedal operating must be very slow.
IFor convenience and safety, it is advisable to
have two men working.
IThe amount of brake fluid required is approxi-
mately 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
49
[W12A0]4-4SERVICE PROCEDURE
12. Brake Fluid

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 measure-
ments must be more than specified.
G4M0436
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 hydrau-
lic 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.
12. Brake Fluid
A: REPLACEMENT
CAUTION:
ITo always maintain the brake fluid
characteristics, replace the brake fluid accord-
ing to maintenance schedule or earlier than
that when used in severe condition.
IThe FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
ICover bleeder with waste cloth, when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
IAvoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
IBe careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
IDuring bleeding operation, keep the brake
reserve tank filled with brake fluid to eliminate entry
of air.
IBrake pedal operating must be very slow.
IFor convenience and safety, it is advisable to
have two men working.
IThe amount of brake fluid required is approxi-
mately 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
49
[W12A0]4-4SERVICE PROCEDURE
12. Brake Fluid

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.
G4M0434
G4M0438
G4M0435
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 again from the twe former procedures
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 running 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 before.
11) Depress brake pedal with a force of approxi-
mately 294 N (30 kg, 66 lb) and hold it there for
approximately 20 seconds. 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.
50
4-4[W12A0]SERVICE PROCEDURE
12. Brake Fluid

13. Proportioning Valve
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 pres-
sure.
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.
B4M1198A
4) For the oil pressure in case of split point, to 4-4 [S1A0].>
B: REMOVAL
B4M1177A
B4M1197A
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/þ2N´m (1.5+0.3/þ0.2kg-m, 10.8+2.2/þ1.4ft-lb)
Proportioning valve to bracket:
18
±5 N´m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
51
[W13C0]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.
2) Remove bolts which secure sensor harness to
strut.
B4M0079A
3) Remove bolts which secure sensor harness to
body.
B4M1181A
4) Remove bolts which secure front ABS sensor to
housing, and remove front ABS sensor.
CAUTION:
IBe careful not to damage pole piece located
at tip of the sensor and teeth faces during
removal.
IDo not pull sensor harness during removal.
B4M1183A
5) Remove front disc brake caliper and disc rotor
from housing after removing front tire.6) Remove front drive shaft and housing and hub
assembly.
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.
G4M0444
2. REAR ABS SENSOR
1) Remove rear seat and disconnect rear ABS
sensor connector.
2) Remove rear sensor harness bracket from rear
trailing link and bracket.
3) Remove rear ABS sensor from rear back plate.
B4M1182A
4) Remove rear tone wheel while removing hub
from housing and hub assembly. [W2A0].>
CAUTION:
IBe careful not to damage pole piece located
at tip of the sensor and teeth faces during
removal.
IDo not pull sensor harness during removal.
B: INSPECTION
1. ABS SENSOR
1) Check pole piece of ABS sensor for foreign par-
ticles or damage. If necessary, clean pole piece or
replace ABS sensor.
52
4-4[W14A1]SERVICE PROCEDURE
14. ABS Sensor

2) Measure ABS sensor resistance.
B4M0248
ABS sensor Terminal No. Standard
Front - LH 1 and 2
1.0±0.2 kW 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.
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 sen-
sor are installed correctly.
B4M1184A
ABS sensor clearance:
Front
0.9 Ð 1.4 mm (0.035 Ð 0.055 in)
Rear
0.7 Ð 1.2 mm (0.028 Ð 0.047 in)
NOTE:
IIf clearance is narrow, adjust by using spacer
(Part No. 26755AA000).
IIf clearance is wide, check the outputted voltage
then replace ABS sensor or tone wheel if the out-
putted voltage is outside the specification.
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 SENSOR.
B4M0118B
C: INSTALLATION
1. FRONT ABS SENSOR
1) Install tone wheel on hub, then install housing
on hub assembly.
2) Temporarily install front ABS sensor on hous-
ing.
CAUTION:
Be careful not to strike ABS sensor's pole
piece and tone wheel's teeth against adjacent
metal parts during installation.
B4M1183A
3) Install front drive shaft to hub spline. 4-2 [W1E0].>
53
[W14C1]4-4SERVICE PROCEDURE
14. ABS Sensor