brake SUBARU OUTBACK 2006 Repair Manual

11 - 6 Maintenance and service
Engine compartment overview „ 2.5-liter non-turbo models 12 3 4 56
7891011
13 12 B004141) Power steering fluid reservoir (page
11-27)
2) Manual transmission oil level gauge
(MT) (page 11-20) or Differential gear
oil level gauge (AT) (page 11-23)
3) Clutch fluid reservoir (page 11-29)
4) Automatic transmi ssion fluid level
gauge (page 11-22)
5) Brake fluid reservoir (page 11-28)
6) Fuse box (page 11-45)
7) Battery (page 11-44)
8) Windshield washer tank (page 11-39)
9) Engine oil filler cap (page 11-9)
10) Engine coolant reservoir (page 11-
14)
11) Radiator cap (page 11-14)
12) Engine oil level gauge (page 11-9)
13) Air cleaner element (page 11-17)

Maintenance and service
11 - 7
– CONTINUED –„ 2.5-liter turbo models 12 4635
13 12 11 10 9 8 7 B004161) Power steering fluid reservoir (page
11-27)
2) Manual transmission oil level gauge
(MT) (page 11-20) or Differential gear
oil level gauge (AT) (page 11-23)
3) Clutch fluid reservoir (page 11-29)
4) Brake fluid reservoir (page 11-28)
5) Automatic transmission fluid level
gauge (page 11-22)
6) Fuse box (page 11-45)
7) Battery (page 11-44)
8) Windshield washer tank (page 11-39)
9) Engine oil filler cap (page 11-9)
10) Engine coolant reservoir (page 11-
14)
11) Engine oil level gauge (page 11-9)
12) Radiator cap (page 11-14)
13) Air cleaner element (page 11-17)

11 - 8 Maintenance and service
„ 3.0-liter models
B0050212 3 4 5
12 1011 9 8 76 1) Power steering fluid reservoir (page
11-27)
2) Differential gear oil level gauge (AT)
(page 11-23)
3) Automatic transmi ssion fluid level
gauge (page 11-22)
4) Brake fluid reservoir (page 11-28)
5) Fuse box (page 11-45)
6) Battery (page 11-44)
7) Windshield washer tank (page 11-39)
8) Engine oil filler cap (page 11-9)
9) Engine coolant reservoir (page 11-
14)
10) Radiator cap (page 11-14)
11) Engine oil level gauge (page 11-9)
12) Air cleaner element (page 11-17)

11 - 2 2 Maintenance and service
Automatic transmission fluid „ Checking the fluid levelThe automatic transmission fluid expands
largely as its temperature rises; the fluid
level differs according to fluid tempera-
ture. Therefore, there are two different
scales for checking the level of hot fluid
and cold fluid on the dipstick.
Though the fluid level can be checked
without warming up the fluid on the
“COLD” range, we recommend checking
the fluid level when the fluid is at operating
temperature.
T Checking the fluid level when the
fluid is hot
Check the fluid level monthly.
1. Drive the vehicle se veral miles to raise
the temperature of the transmission fluid
up to normal operating temperature; 158
to 176 ° F (70 to 80 ° C) is normal.
2. Park the vehicle on a level surface and
set the parking brake.
3. First shift the selector lever in each po-
sition. Then shift it in the “P” position, and
run the engine at idling speed. 4-speed automatic transmission
1) Yellow handle
5-speed automatic transmission
1) Yellow handle 1) HOT range
2) COLD range
3) Upper level
4) Lower level
4. Pull out the dipstick and check the fluid
level on the gauge. If it is below the lower
level on the “HOT” range, add the recom-
mended automatic transmission fluid up to
the upper level.
T Checking the fluid level when the
fluid is cold
When the fluid level has to be checked
without time to warm up the automatic
transmission, check to see that the fluid
level is between the lower level and upper
level on the “COLD” range. If it is below
that range, add fluid up to the upper level.
Be careful not to overfill.1
B00428
1
B00429 3
43
4
2 1 B00370

11 - 2 8 Maintenance and service
Brake fluid „ Checking the fluid level
Check the fluid level monthly.
Check the fluid level on the outside of the
reservoir. If the level is below “MIN”, add
the recommended brake fluid to “MAX”. Use only brake fluid from a sealed con-
tainer.
„ Recommended brake fluid FMVSS No. 116, fresh DOT 3 or 4 brake flu-
id
y Never let brake fluid contact your
eyes because brake fluid can be
harmful to your eyes. If brake fluid
gets in your eyes, immediately
flush them thoroughly with clean
water. For safety, when perform-
ing this work, wearing eye protec-
tion is advisable.
y Brake fluid absorbs moisture from
the air. Any absorbed moisture
can cause a dangerous loss of
braking performance.
y If the vehicle requires frequent re-
filling, there may be a leak. If you
suspect a problem, have the vehi-
cle checked at your SUBARU
dealer.
y Never use different brands of
brake fluid togeth er. Also, avoid
mixing DOT 3 and DOT 4 brake flu-
ids even if they are of the same
brand. y When adding brake fluid, be care-
ful not to allow any dirt into the
reservoir.
y Never splash the brake fluid over
painted surfaces or rubber parts.
Alcohol contained in the brake flu-
id may damage them.
y Be careful not to spill brake fluid
when adding it. If brake fluid
touches the exhaust pipe, it may
cause a bad smell, smoke, and/or
a fire. If brake fluid gets on the ex-
haust pipe, be sure to wipe it off.
B00125

Maintenance and service
11 - 2 9
Clutch fluid (MT vehicles) „ Checking the fluid level
Check the fluid level on the outside of the
reservoir. If the leve l is below “MIN” level
mark, add the recommended clutch fluid
to “MAX” level mark.
Use only clutch fluid from a sealed con-
tainer. „ Recommended clutch fluid FMVSS No. 116, fresh DOT 3 or 4 brake flu-
id
Never let clutch fluid contact your
eyes because clutch fluid can be
harmful to your eyes. If clutch fluid
gets in your eyes, immediately flush
them thoroughly with clean water.
For safety, when performing this
work, wearing eye protection is ad-
visable.
y Clutch fluid absorbs moisture
from the air. Any absorbed mois-
ture can cause improper clutch
operation.
y If the vehicle requires frequent re-
filling, there may be a leak. If you
suspect a problem, have the vehi-
cle checked at your SUBARU
dealer.
y Never use different brands of
clutch fluid together.
y When clutch fluid is added, be
careful not to a llow any dirt into
the tank. y Never splash the clutch fluid over
painted surfaces or rubber parts.
Alcohol contained in the clutch
fluid may damage them.
y Be careful not to spill clutch fluid
when adding it. If clutch fluid
touches the exhaus t pipe, it may
cause a bad smell, smoke, and/or
a fire. If clutch fluid gets on the ex-
haust pipe, be sure to wipe it off.
B00126Avoid mixing DOT 3 and DOT 4
brake fluids even if they are of the
same brand.

11 - 3 0 Maintenance and service
Brake booster If the brake booster does not operate as
described in the following, 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 slight-
ly 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 ap-
proximately one minute then turn it off.
Depress the brake pedal several times to
check the brake booster. The brake boost-
er operates properly if the pedal stroke de-
creases with each depression. Brake pedal Check the brake pedal free play and re-
serve distance according to the mainte-
nance schedule in the “Warranty and
Maintenance Booklet”.
„ Checking the brake pedal free
play
1) 0.02 – 0.08 in (0.5 – 2.0 mm)
Stop the engine and firmly depress the
brake pedal several times. Lightly pull the
brake pedal up with one finger to check
the free play with a force of less than 2 lbs
(10 N, 1 kg).
If the free play is not within proper specifi-
cation, contact your SUBARU dealer. „ Checking the brake pedal re-
serve distance
1) More than 2.56 in (65 mm)
Depress the pedal with a force of approxi-
mately 66 lbs (294 N, 30 kg) 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.1 B003231 B00324

Maintenance and service
11 - 3 1
– CONTINUED –Clutch pedal (Manual trans-
mission vehicles) Check the clutch pedal free play and re-
serve distance according to the mainte-
nance schedule in the “Warranty and
Maintenance Booklet”.
„ Checking the clutch functionCheck the clutch engagement and disen-
gagement.
1. With the engine idling, check that there
are no abnormal noises when the clutch
pedal is depressed, and that shifting into
1st or reverse feels smooth.
2. Start the vehicle by releasing the pedal
slowly to check that the engine and trans-
mission smoothly couple without any sign
of slippage. „ Checking the clutch pedal
free play
1) 0.16 – 0.51 in (4.0 – 13.0 mm)
Lightly press the clutch pedal down with
your finger until you feel resistance, and
check the free play.
If the free play is not within proper specifi-
cation, contact your SUBARU dealer. Replacement of brake pad
and lining
The right front disc brake and the right rear
disc brake have audible wear indicators
on the brake pads. If the brake pads wear
close to their service limit, the wear indica-
tor makes a very audible scraping noise
when the brake pedal is applied.
If you hear this scraping noise each time1 B00323
If you continue to drive despite the
scraping noise from the audible
brake pad wear indicator, it will re-
sult in the need for costly brake ro-
tor repair or replacement.
700040

11 - 3 2 Maintenance and service
you apply the brake pedal, have the brake
pads serviced by your SUBARU dealer as
soon as possible.
„ Breaking-in of new brake
pads and liningsWhen replacing the brake pad or lining,
use only genuine SUBARU parts. After re-
placement, the new parts must be broken
in as follows:
T 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.
T Parking brake lining
1. Drive the vehicle at a speed of approx- imately 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 approximately 33 lbs [147 N, 15
kg].)
3. Drive the vehicle for approximately 220
yards (200 meters) in this condition.
4. Wait 5 to 10 minutes for the parking
brake to cool down. Repeat this proce-
dure.
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:
5 – 6 notches / 44 lbs (196 N, 20 kg) Parking brake stroke
Check the parking brake stroke according
to the maintenance schedule in the “War-
ranty and Maintenance Booklet”. When
the parking brake is properly adjusted,
braking power is fully applied by pulling
the lever up five to six notches gently but
firmly (approximately 44 lbs, 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.A safe location and situation should
be selected for break-in driving.
Pulling the parking brake lever too
forcefully may cause the rear
wheels to lock. To avoid this, be cer-
tain to pull the lever up slowly and
gently. B00127

11 - 3 4 Maintenance and service
goes off a few minutes later. If the low tire
pressure warning light does not go off, the
tire pressure monitoring system may not
be functioning normally. In this event, go
to a SUBARU dealer to have the system
inspected as soon as possible.
While the vehicle is driven, friction be-
tween tires and the road surface causes
the tires to warm up. After illumination of
the low tire pressure warning light, any in-
crease in the tire pressures caused by an
increase in the outside air temperature or
by an increase in the temperature in the
tires can cause the low tire pressure warn-
ing light to go off.
System resetting is necessary when the
wheels are changed (for example, a
switch to snow tires) and new TPMS
valves are installed on the newly fitted
wheels. Have this work performed by a
SUBARU dealer following wheel replace-
ment.
It may not be possible to install TPMS
valves on certain wheels that are on the
market. Therefore, if you change the
wheels (for example, a switch to snow
tires), use wheels that have the same part
number as the standard-equipment
wheels. Without four operational TPMS
valve/sensors on the wheels, the TPMS will not fully function and the warning light
in the instrument panel will flash.
When a tire is replaced, adjustments are
necessary to ensure continued normal op-
eration of the tire pr essure monitoring sys-
tem. As with wheel replacement, there-
fore, you should have the work performed
by a SUBARU dealer.
„ 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 immediate-
ly if you find any problem.
NOTE y When the wheels and tires strikeIf the low tire pressure warning light
does not come on br iefly after the ig-
nition switch is turned ON or the
light is flashing, you should have
your Tire Pressure Monitoring Sys-
tem checked at a SUBARU dealer as
soon as possible.
If this light comes on while driving,
never brake suddenly and keep driv-
ing straight ahead while gradually
reducing speed. Then slowly pull off
the road to a safe place. Otherwise
an accident involving serious vehi-
cle damage and serious personal in-
jury could occur. If this light still comes on while driv-
ing after adjusting the tire pressure,
a tire may have significant damage
and a fast leak that causes the tire to
lose air rapidly. If you have a flat tire,
replace it with a spare tire as soon
as possible.
When a spare tire is mounted or a
wheel rim is replaced without the
original pressure sensor/transmitter
being transferred, the low tire pres-
sure warning light will flash. This in-
dicates the TPMS is unable to moni-
tor all four road wheels. Contact
your SUBARU dealer as soon as
possible for tire and sensor replace-
ment and/or system resetting. If the
light flashes, promptly contact a
SUBARU dealer to have the system
inspected.