service SUBARU OUTBACK 2003 3.G Service Manual

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SAE viscosity No. and Applicable Temperature
OM-H0212
Rear differential gear oil
Checking the gear oil level CAUTION
If the vehicle requires frequent refilling, there may be an oil leak. If you suspect a problem, have the vehicle checked at your
SUBARU dealer.
Your vehicle may be equipped with a rear differential protector. The
differential protector provides protection to the rear differential assem-
bly during off-road use. Removal of the rear differential protector is not
required when checking the oil level.

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SAE viscosity No. and Applicable Temperature
OM-H0205
Power steering fluid
Checking the fluid level
WARNING
Be careful not to burn yourself because the fluid may be hot.
CAUTION
When power steering fluid is being added, use only clean fluid,
and be careful not to allow any dirt into the tank. And never use
different brands together. Avoid spilling fluid when adding it in the tank.
The power steering fluid expands greatly as its temperature rises; the
fluid level differs according to fluid temperature. Therefore, the reser-
voir tank has two different checking ranges for hot and cold fluids.
Check the power steering fluid level monthly.
1. Park the vehicle on a level surface, and stop the engine.
2. Check the fluid level of the reservoir tank.
When the fluid is hot after the vehicle has been run: Check that the oillevel is between “HOT MIN ” and “HOT MAX ” on the surface of the
reservoir tank.

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If the vehicle requires frequent refilling, there may be a leak. If
you suspect a problem, have the vehicle checked at your
SUBARU dealer.
CAUTION
Never use different brands of brake fluid together.
When adding brake fluid, be careful not to allow any dirt into
the reservoir. Never splash the brake fluid over painted surfaces or rubber
parts. Alcohol contained in the brake fluid may damage them.
Check the fluid level monthly.
HBB004GB
“MIN ” level
mark
“ MAX ” level mark
Check the fluid level on the outside of the reservoir. If the level is be- low “MIN” , add the recommended brake fluid to “MAX”.
Use only brake fluid from a sealed container. Recommended brake fluid
FMVSS No. 116, fresh DOT 3 or 4 brake fluid

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Recommended clutch fluid
FMVSS No. 116, fresh DOT 3 or 4 brake fluid
Brake booster
If the brake booster does not operate as described below, have it
checked by your SUBARU dealer.
1. With the engine off, depress the brake pedal several times, applying
the same pedal force each time. The distance the pedal travels should
not vary.
2. With the brake pedal depressed, start the engine. The pedal should
move slightly down to the floor.
3. With the brake pedal depressed, stop the engine and keep the pedal
depressed for 30 seconds. The pedal height should not change.
4. Start the engine again and run for about one minute then turn it off.
Depress the brake pedal several times to check the brake booster.
Brake booster operates properly if the pedal stroke decreases with each
depression.

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and measure the distance between the upper surface of the pedal
pad and the floor.
When the measurement is smaller than the specification, or when the
pedal does not operate smoothly, contact with your SUBARU dealer.
Clutch pedal (Manual transmission vehicles)
Check the clutch pedal free play and reserve distance according to the
maintenance schedule in the “Warranty and Maintenance Booklet ”.
Checking the clutch function
Check the clutch engagement and disengagement.
1. With the engine idling, check that there are no abnormal noises
when the clutch pedal is depressed, and that shifting into 1st or re-
verse feels smooth.
2. Start the vehicle by releasing the pedal slowly to check that the en-gine and transmission smoothly couple without any sign of slippage. Checking the clutch pedal free play
OM-H0224
0.16 —
0.51 in
(4.0 — 13.0 mm)
Lightly press the clutch pedal down with your finger until you feel re-
sistance, and check the free play.
If the free play is not within proper specification, contact your
SUBARU dealer.

11-36Replacement of brake pad and lining
CAUTION
If you continue to drive despite the scraping noise from the audi-
ble brake pad wear indicator, it will result in the need for costlybrake rotor repair or replacement.
OM-H0163
The front disc brakes and the right rear disc brake have an audible wear
indicators on the brake pads. If the brake pads wear close to their ser-
vice limit, the wear indicator makes a very audible scraping noise whenthe brake pedal is applied.
If you hear this scraping noise each time you apply the brake pedal, have the brake pads serviced by your SUBARU dealer as soon as pos-sible.
Breaking-in of new brake pads and linings
When replacing the brake pad or lining, use only genuine SUBARU
parts. After replacement, the new parts must be broken in as follows: n Brake pad and lining
While maintaining a speed of 30 to 40 mph (50 to 65 km/h), step on
the brake pedal lightly. Repeat this five or more times.

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n
Parking brake lining
WARNING
A safe location and situation should be selected for break-in driv- ing.
CAUTION
Pulling the parking brake lever too forcefully may cause the rear
wheels to lock. To avoid this, be certain to pull the lever up slowly
and gently.
1. Drive the vehicle at a speed of about 22 mph (35 km/h).
2. With the parking brake release button pushed in, pull the parking
brake lever SLOWLY and GENTLY. (Pulling with a force of approxi-mately 33 lb [147 N, 15 kg].)
3. Drive the vehicle for about 220 yards (200 meters) in this condition.
4. Wait 5 to 10 minutes for the parking brake to cool down. Repeat
this procedure.
5. Check the parking brake stroke. If the parking brake stroke is out
of the specified range, adjust it by turning the adjusting nut located
on the parking brake lever.Parking brake stroke: 7 — 8 notches / 44 lb (196 N, 20 kg)
Parking brake stroke
Check the parking brake stroke according to the maintenance schedule in the “Warranty and Maintenance Booklet ”. When the parking brake is
properly adjusted, braking power is fully applied by pulling the lever up
seven to eight notches gently but firmly (about 44 lb, 196 N, 20 kg). If the
parking brake lever stroke is not within the specified range, have the
brake system checked and adjusted at your SUBARU dealer.

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Winter (snow) tires
Winter tires are best suited for driving on snow-covered and icy
roads. However winter tires do not perform as well as summer tires
and all season tires on roads other than snow-covered and icy roads.
Tire inspection
Check on a daily basis that the tires are free from serious damage, nails,
and stones. At the same time, check the tires for abnormal wear.
Contact your SUBARU dealer immediately if you find any problem. NOTE When the wheels and tires strike curbs or are subjected to harsh
treatment as when the vehicle is driven on a rough surface, they can suffer damage that cannot be seen with the naked eye. This type of
damage does not become evident until time has passed. Try not todrive over curbs, potholes or on other rough surfaces. If doing so is
unavoidable, keep the vehicle ’s speed down to a walking pace or
less, and approach the curbs as squarely as possible. Also, makesure the tires are not pressed against the curb when you park thevehicle. If you feel unusual vibration while driving or find it difficult to
steer the vehicle in a straight line, one of the tires and/or wheelsmay be damaged. Drive slowly to the nearest authorized SUBARUdealer and have the vehicle inspected. Tire pressures and wear
Maintaining the correct tire pressures helps to maximize the tires ’ service
lives and is essential for good running performance. Check and, if nec-
essary, adjust the pressure of each tire (including the spare) at least
once a month (for example, during a fuel stop) and before any long jour-
ney.
Check the tire pressures when the tires are cold. Use a pressure gauge
to adjust the tire pressures to the values shown on the tire placard. The
tire placard is located on the door pillar on the driver ’s side.

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Correct tire pressure (tread worn evenly)
HGB033AA
Roadholding is good, and steering is responsive. Rolling resistance is
low, so fuel consumption is also lower.
Abnormally low tire pressure (tread worn at shoulders)
HSB012AA
Rolling resistance is high, so fuel consumption is also higher.

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NOTE Loss of correct wheel alignment* causes the tires to wear on one side and reduces the vehicle
’s running stability. Contact your
SUBARU dealer if you notice abnormal tire wear.
* : The suspension system is designed to hold each wheel at a certain alignment
(relative to the other wheels and to the road) for optimum straight-line stability and
cornering performance. Wear indicators
Each tire incorporates a tread wear indicator, which becomes visible
when the depth of the tread grooves decreases to 0.063 in. (1.6 mm). A
tire must be replaced when the tread wear indicator appears as a solid
band across the tread.
OM-H0231
WARNING
When a tire ’s tread wear indicator becomes visible, the tire is
worn beyond the acceptable limit and must be replaced immedi-
ately. With a tire in this condition, driving at high speeds in wetweather can cause the vehicle to hydroplane. The resulting lossof vehicle control can lead to an accident.
NOTE
For safety, inspect the tire tread regularly and replace the tires be- fore their tread wear indicators become visible. A) New tread
B) Worn tread
1) Tread wear indicator