Subaru Legacy (2005 year). Service manual — part 818
BRAKE
BR
Page
General Description . . . . . . . . . . . . . . . . . . . . . 2
Front Brake Pad . . . . . . . . . . . . . . . . . . . . . . 16
Front Disc Rotor . . . . . . . . . . . . . . . . . . . . . . 19
Front Disc Brake Assembly. . . . . . . . . . . . . . . . . ...20
Rear Brake Pad. . . . . . . . . . . . . . . . . . . . . . .25
Rear Disc Rotor. . . . . . . . . . . . . . . . . . . . . . .26
Rear Disc Brake Assembly . . . . . . . . . . . . . . . . . ...28
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . .30
Brake Booster . . . . . . . . . . . . . . . . . . . . . . ...33
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . 37
Air Bleeding. . . . . . . . . . . . . . . . . . . . . . . ...38
Brake Hose . . . . . . . . . . . . . . . . . . . . . . . ...40
Brake Pipe. . . . . . . . . . . . . . . . . . . . . . . . .42
Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . ...43
Stop Light Switch . . . . . . . . . . . . . . . . . . . . . ..45
General Diagnostic Table. . . . . . . . . . . . . . . . . . ..47
BR-2
BRAKE
General Description
1. General Description
A: SPECIFICATION
NOTE:
Refer to “PB” section for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General Descrip-
tion.>
Model
2.0 i, 2.5 i
3.0 R (EH model), OUT-
BACK 2.5 i, OUTBACK
3.0 R
2.0 GT, 3.0 R (Except for
EH model)
Front disc
brake
Size
15-inch type
16-inch type
17-inch type
Type
Disc (Floating type, ventilated)
Effective disc diameter
mm (in)
228 (8.98)
244 (9.61)
261 (10.28)
Disc thickness
× Outer
diameter
mm (in)
24
× 277 (0.94 × 10.91)
24
× 294 (0.94 × 11.57)
30
× 316 (1.18 × 12.44)
Effective cylinder diameter
42.8 (1.685)
× 2
Pad dimensions
(length
× width × thick-
ness)
mm (in)
117.8
× 50.5 × 11.0 (4.638 × 1.988 × 0.433)
130.0
× 53.5 × 11.0
(5.118
× 2.106 × 0.433)
Clearance adjustment
Automatic adjustment
Rear disc
brake
Size
15-inch type
Type
Disc (Floating type, solid)
Disc (Floating type, venti-
lated)
Effective disc diameter
mm (in)
238 (9.37)
254 (10.0)
Disc thickness
× Outer
diameter
mm (in)
10
× 274 (0.39 × 10.79)
18
× 290 (0.71 × 11.42)
Effective cylinder
diameter
mm (in)
38.1 (1.500)
Pad dimensions
(length
× width × thick-
ness)
mm (in)
92.0
× 33.0 × 9.0 (3.622 × 1.299 × 0.354)
82.4
× 33.7 × 9.0
(3.244
× 1.327 × 0.354)
Clearance adjustment
Automatic adjustment
Master
cylinder
Type
Tandem
Effective diameter
mm (in)
23.8 (15/16)
Reservoir type
Sealed type
Brake fluid reservoir
capacity
cm
3
(cu
in)
205 (12.51)
Brake
booster
Type
Vacuum suspended
Effective diameter
mm (in)
208 + 229 (8.19 + 9.02)
Brake line
Dual circuit system
Brake fluid
CAUTION:
• Avoid mixing brake fluid of different
brands to prevent fluid performance from
degrading.
• When filling brake fluid, be careful not to
allow any dust into the reservoir.
• Use fresh brake fluid when replacing or
refilling fluid.
FMVSS No. 116, DOT3
BR-3
BRAKE
General Description
Item
Specification
Limit
Front brake
Pad thickness
mm (in)
Except 17-inch
type
11 (0.43)
1.5 (0.059)
17-inch type
11 (0.43)
1.5 (0.059)
Disc thickness
mm (in)
Except 17-inch
type
24 (0.94)
22 (0.87)
17-inch type
30 (1.18)
28 (1.10)
Disc runout
mm (in)
—
0.05 (0.0020)
Rear brake (Disc
type)
Pad thickness
mm (in)
Solid disc
9.0 (0.354)
1.5 (0.059)
Ventilated disc
9.0 (0.354)
1.5 (0.059)
Disc thickness
mm (in)
Solid disc
10 (0.39)
8.5 (0.335)
Ventilated disc
18 (0.71)
16 (0.63)
Disc runout
mm (in)
—
0.05 (0.0020)
Parking brake
Inside diameter
mm (in)
170 (6.69)
171 (6.73)
Lining thickness
mm (in)
3.2 (0.126)
1.5 (0.059)
Lever stroke
5 — 6 notches/200 N (20 kgf, 45 lbf)
Brake pedal force
N (kgf, lbf)
Fluid pressure kPa (kgf/cm
2
, psi)
15-inch type
16-inch type
17-inch type
Brake
booster
Brake fluid pressure without
engine running
147 (15, 33)
545 (6, 79)
294 (30, 66)
1,564 (16, 227)
Brake fluid pressure with
engine running and vacuum
at 66.7 kPa (500 mmHg,
19.69 inHg)
147 (15, 33)
6,003 (61, 871)
5,381 (55, 780)
4,963 (51, 720)
294 (30, 66)
11,273 (115, 1,635) 10,982 (112, 1,593) 10,055 (103, 1,458)
Brake pedal
Free play
mm (in)
0.5 — 2 (0.02 — 0.08)
[When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lbf).]
BR-4
BRAKE
General Description
B: COMPONENT
1. FRONT DISK BRAKE
• Except for EC, EK, OUTBACK model
(A)
15, 16-inch type
(B)
17-inch type
(1)
Caliper body
(9)
Support
(17)
Bushing
(2)
Air bleeder screw
(10)
Pad clip
(3)
Guide pin (Green)
(11)
Outer shim
Tightening torque: N
⋅
m (kgf-m, ft-lb)
(4)
Pin boot
(12)
Inner shim
T1: 8 (0.8, 5.9)
(5)
Piston seal
(13)
Pad (Outside)
T2: 27 (2.8, 19.9)
(6)
Piston
(14)
Pad (Inside)
T3: 80 (8.2, 59)
(7)
Piston boot
(15)
Disc rotor
(8)
Lock pin (Yellow)
(16)
Disc cover
BR-00332
( 1 )
( 2 )
( 3 )
( 4 )
( 4 )
( 1 7 )
( 1 0 )
( 1 1 )
( 1 1 )
( 1 2 )
( 1 2 )
( 1 6 )
( A )
( B )
( 1 3 )
( 1 4 )
( 1 5 )
( 5 )
( 6 )
( 7 )
( 9 )
( 8 )
T2
T3
( 1 1 )
( 1 1 )
( 1 2 )
( 1 2 )
( 1 3 )
( 1 4 )
( 1 3 )
T1
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