1986 Subaru BRAT Repair Manual

The 1986 Subaru BRAT (Bi-drive Recreational All-terrain Transporter) is a compact pickup truck featuring four-wheel drive, dual-range transmission, and the distinctive rear-facing jump seats in the cargo bed. This repair manual covers maintenance, troubleshooting, and repair procedures for the 1.8L EA82 engine, manual and automatic transmissions, 4WD system, brakes, suspension, electrical systems, and body components. Below are key sections for specifications, maintenance schedules, repair procedures, and troubleshooting.

Vehicle Specifications

Key specifications for the 1986 Subaru BRAT including engine, dimensions, and performance data.

Maintenance Schedule

Recommended maintenance intervals for optimal performance and longevity.

1. Oil Change: Every 3,000 miles or 3 months
2. Spark Plugs: Replace every 30,000 miles
3. Air Filter: Inspect every 15,000 miles, replace as needed
4. Timing Belts: Replace every 60,000 miles
5. Coolant Flush: Every 30,000 miles or 2 years
6. Brake Fluid: Replace every 2 years
7. Transmission Fluid: Check every 15,000 miles
8. 4WD System: Lubricate every 30,000 miles

WARNING! Always use jack stands when working under vehicle. Disconnect battery before electrical work.

Engine Repair

Procedures for EA82 engine maintenance and repair.

1. Spark Plug Replacement: Gap 0.039-0.043 inches, torque to 18 ft-lbs
2. Valve Adjustment: Cold engine, intake 0.006", exhaust 0.010"
3. Timing Belt: Align marks on pulleys and covers during replacement
4. Carburetor Adjustment: Idle speed 750 rpm, mixture 2.5 turns out
5. Compression Test: Should be 142-171 psi, within 14 psi cylinder to cylinder
6. Oil Pressure: 57 psi at 3000 rpm when warm

CAUTION! Engine components become extremely hot during operation. Allow to cool before servicing.

Transmission & Drivetrain

• Manual Transmission: GL-4 75W-90 gear oil, 3.7 pints capacity
• Automatic Transmission: Dexron II ATF, 7.4 quarts total
• Transfer Case: GL-5 80W-90, 1.1 pints
• Front Differential: GL-5 80W-90, 1.1 pints
• Rear Differential: GL-5 80W-90, 1.1 pints
• Clutch: Hydraulic system, bleed when spongy
• CV Joints: Repack with grease every 30,000 miles

Brake System

Brake maintenance and repair procedures.

Front Disc Brakes: Pad thickness minimum 0.079 inches, rotor minimum thickness 0.394 inches. Rear Drum Brakes: Shoe thickness minimum 0.039 inches, drum maximum diameter 7.087 inches.

Bleeding Sequence: Right rear, left rear, right front, left front. Master Cylinder: Bench bleed before installation. Brake Fluid: DOT 3 only.

Suspension & Steering

Front: MacPherson struts, coil springs. Rear: Trailing arms, coil springs.

1. Strut Replacement: Support vehicle, remove wheel, disconnect sway bar link
2. Ball Joints: Check for play, replace if movement exceeds 0.118 inches
3. Tie Rod Ends: Replace if play detected during shake test
4. Wheel Alignment: Toe-in 0.08 ± 0.08 inches, camber -0°20' ± 45'
5. Power Steering: Use Dexron II ATF, check belt tension

Tip: Always replace suspension components in pairs for balanced handling.

Electrical System

12-volt negative ground system with 55-amp alternator.

1. Battery: Group 24, 450 CCA minimum
2. Alternator: Output 55 amps at 2000 rpm
3. Starter: 1.4 kW, draw 180 amps maximum
4. Fuses: 10-30 amp blade-type fuses in under-dash panel
5. Headlights: Sealed beam, 65/45 watt
6. Spark Plug Wires: Resistance 16K ohms per foot maximum

WARNING! Disconnect battery before electrical repairs to prevent shorts and injury.

Body & Interior

Steel unibody construction with plastic bed liner and removable T-top roofs.

4WD System

Part-time 4WD with dual-range transfer case. High range for normal driving, low range for off-road or heavy loads.

Engagement: Stop vehicle, depress clutch (manual), move lever to desired range. Front hubs automatically lock when 4WD engaged.

Troubleshooting

Technical Support: Subaru dealership or certified Subaru mechanic recommended for complex repairs.

Parts Source: Genuine Subaru parts recommended for optimal performance and fit.