SUBARU LEGACY 1999 Service Repair Manual

C: DISASSEMBLY
1. EXCEPT 2500 cc MODEL
B4M1152D
(1) Caliper body
(2) Air bleeder screw
(3) Guide pin (Green)
(4) Pin boot
(5) Piston seal
(6) Piston
(7) Piston boot
(8) Lock pin (Yellow)(9) Support
(10) Pad clip
(11) Outer shim
(12) Inner shim
(13) Pad (Outside)
(14) Pad (Inside)
(15) Disc rotor
(16) Disc coverTightening torque: N´m (kg-m, ft-lb)
T1:
8±1 (0.8±0.1, 5.8±0.7)
T2:18±5 (1.8±0.5, 13.0±3.6)
T3:37±5 (3.8±0.5, 27.5±3.6)
T4:78±10 (8.0±1.0, 58±7)
1) Clean mud and foreign particles from caliper
body assembly and support.
CAUTION:
Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
20
4-4[W1C1]SERVICE PROCEDURE
1. Front Disc Brake

2) Gradually supply compressed air via caliper
body brake hose to force piston out.
CAUTION:
IPlace a wooden block as shown in Figure to
prevent damage to piston.
IDo not apply excessively high-pressure.
B4M1174A
3) Remove piston boot.
4) Remove piston seal from caliper body cylinder.
B4M1173A
5) Remove guide pin and boot from caliper body.
21
[W1C1]4-4SERVICE PROCEDURE
1. Front Disc Brake

2. 2500 cc MODEL
B4M1151D
(1) Caliper body
(2) Air bleeder screw
(3) Guide pin (Green)
(4) Pin boot
(5) Piston seal
(6) Piston
(7) Piston boot
(8) Boot ring(9) Lock pin (Yellow)
(10) Support
(11) Pad clip
(12) Outer shim
(13) Inner shim
(14) Pad (Outside)
(15) Pad (Inside)
(16) Disc rotor(17) Disc cover
Tightening torque: N´m (kg-m, ft-lb)
T1:
8±1 (0.8±0.1, 5.8±0.7)
T2:18±5 (1.8±0.5, 13.0±3.6)
T3:37±5 (3.8±0.5, 27.5±3.6)
T4:78±10 (8.0±1.0, 58±7)
1) Clean mud and foreign particles from caliper
body assembly and support.
CAUTION:
Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
22
4-4[W1C2]SERVICE PROCEDURE
1. Front Disc Brake

2) Using a standard screwdriver, remove boot ring
from piston.
B4M1164A
3) Remove boot from piston end.
4) Gradually supply compressed air via caliper
body brake hose to force piston out.
CAUTION:
Place a wooden block as shown in Figure to
prevent damage to piston.
B4M1165A
5) Remove piston seal from caliper body cylinder.
B4M1172A
6) Remove lock pin boot and guide pin boot.
D: INSPECTION
1) Repair or replace faulty parts.
2) Check caliper body and piston for uneven wear,
damage or rust.
3) Check rubber parts for damage or deterioration.
E: ASSEMBLY
1. EXCEPT 2500 cc MODEL
1) Clean caliper body interior using brake fluid.2) Apply a coat of brake fluid to piston seal and fit
piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner
surface of cylinder and outer surface of piston.
4) Apply a coat of specified grease to boot and fit
in groove on ends of cylinder and install piston boot
onto cylinder.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
5) Insert piston into cylinder.
CAUTION:
Do not force piston into cylinder.
B4M1175A
6) Position boot in grooves on cylinder and piston.
B4M0072A
7) Apply a coat of specified grease to lock pin and
guide pin outer surface, cylinder inner surface, and
boot grooves.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
B4M1176A
8) Install lock and guide pin boot on support.
23
[W1E1]4-4SERVICE PROCEDURE
1. Front Disc Brake

2. 2500 cc MODEL
1) Clean caliper body interior using brake fluid.
2) Apply a coat of brake fluid to piston seal and fit
piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner
surface of cylinder and outer surface of piston.
4) Insert piston into cylinder.
CAUTION:
Do not force piston into cylinder.
B4M0771A
5) Apply a coat of specified grease to boot and fit
in groove on ends of cylinder and piston.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
To facilitate installation, fit boot starting with piston
end.
G4M0373
6) Position boot in grooves on cylinder and piston.
7) Install boot ring. Be careful not scratch boot.8) Apply a coat of specified grease to lock pin and
guide pin, outer surface, cylinder inner surface,
and boot grooves.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
B4M1176A
9) Install lock pin boot and guide pin boot on sup-
port.
F: INSTALLATION
1) Install disc rotor on hub.
2) Install support on housing.
Tightening torque:
78
±10 N´m (8±1 kg-m, 58±7 ft-lb)
CAUTION:
IAlways replace the pads for both the left and
right wheels at the same time. Also replace pad
clips if they are twisted or worn.
IA wear indicator is provided on the inner
disc brake pad. If the pad wears down to such
an extent that the end of the wear indicator
contacts the disc rotor, a squeaking sound is
produced as the wheel rotates. If this sound is
heard, replace the pad.
IWhen replacing the pad, replace pads of the
right and left wheels at the same time.
3) Apply thin coat of PBC GREASE (Part No.
003607000) to the frictional portion between pad
and pad clip.
B4M1169A
4) Install pads, rubber coated shim and stainless
shim on support.
5) Install caliper body on support.
24
4-4[W1E2]SERVICE PROCEDURE
1. Front Disc Brake

Tightening torque:
39
±5 N´m (4±0.5 kg-m, 28.9±3.6 ft-lb)
6) Connect brake hose.
Tightening torque:
18
±3 N´m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
CAUTION:
Replace brake hose gaskets with new ones.
7) Bleed air from brake system.
2. Rear Disc Brake
A: ON-CAR SERVICE
1. PAD
1) Remove lock pin.
G4M0378
2) Raise caliper body.
3) Remove pad from support.
G4M0379
25
[W2A1]4-4SERVICE PROCEDURE
2. Rear Disc Brake

Tightening torque:
39
±5 N´m (4±0.5 kg-m, 28.9±3.6 ft-lb)
6) Connect brake hose.
Tightening torque:
18
±3 N´m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
CAUTION:
Replace brake hose gaskets with new ones.
7) Bleed air from brake system.
2. Rear Disc Brake
A: ON-CAR SERVICE
1. PAD
1) Remove lock pin.
G4M0378
2) Raise caliper body.
3) Remove pad from support.
G4M0379
25
[W2A1]4-4SERVICE PROCEDURE
2. Rear Disc Brake

4) Check pad thickness (including back metal).
Pad thickness: A
Standard value
15.0 mm (0.591 in)
Wear limit
6.5 mm (0.256 in)
G4M0362
CAUTION:
IAlways replace the pads for both the left and
right wheels at the same time. Also replace pad
clips if they are twisted or worn.
IA wear indicator is provided on the inner
disc brake pad. If the pad wears down to such
an extent that the end of the wear indicator
contacts the disc rotor, a squeaking sound is
produced as the wheel rotates. If this sound is
heard, replace the pad.
IReplace pad if there is oil or grease on it.
5) Apply thin coat of PBC GREASE (Part No.
03607000) to the frictional portion between pad
and pad clip.
6) Install pad on support.
G4M0363
7) Install caliper body on support.
Tightening torque:
20
±4 N´m (2.0±0.4 kg-m, 14.5±2.9 ft-lb)
NOTE:
If it is difficult to push piston during pad
replacement, loosen air bleeder to facilitate work.
2. DISC ROTOR
1) Install disc rotor by tightening the five wheel
nuts.
2) Set a dial gauge on the disc rotor. Turn disc
rotor to check runout.
G4M0382
NOTE:
Make sure that dial gauge is set 5 mm (0.20 in)
inward of rotor outer perimeter.
Disc rotor runout limit:
0.1 mm (0.004 in)
3) Measure disc rotor thickness.
G4M0383
NOTE:
Make sure that micrometer is set 5 mm (0.20 in)
inward of rotor outer perimeter.
Disc rotor thickness: A
Standard value
10 mm (0.39 in)
Service limit
8.5 mm (0.335 in)
NOTE:
When removing disc rotor, refer to instructions
under Parking Brake. <Ref. to 4-4 [W4A0].>
26
4-4[W2A2]SERVICE PROCEDURE
2. Rear Disc Brake

B: REMOVAL
B4M1124A
(1) Guide pin
(2) Lock pin
(3) Lock pin boot
(4) Lock pin sleeve
(5) Air bleeder screw
(6) Guide pin boot
(7) Caliper body
(8) Piston seal
(9) Piston(10) Piston boot
(11) Boot ring
(12) Pad clip
(13) Shim
(14) Inner shim
(15) Inner pad
(16) Outer pad
(17) Support
(18) Outer shim(19) Disc rotor
Tightening torque: N´m (kg-m, ft-lb)
T1:
8±1 (0.8±0.1, 5.8±0.7)
T2:20±4 (2.0±0.4, 14.5±2.9)
T3:26±5 (2.7±0.5, 19.5±3.6)
T4:52±6 (5.3±0.6, 38.3±4.3)
1) Lift-up vehicle and remove wheels. 2) Disconnect brake hose from caliper body
assembly.
CAUTION:
Do not allow brake fluid to come in contact with
vehicle body; wipe off completely if spilled.
G4M0384
3) Remove lock pin.
27
[W2B0]4-4SERVICE PROCEDURE
2. Rear Disc Brake

4) Raise caliper body and move it toward vehicle
center to separate it from support.
5) Remove support from back plate.
NOTE:
Remove support only when replacing it or the rotor.
It need not be removed when servicing caliper
body assembly.
6) Clean mud and foreign particles from caliper
body assembly and support.
CAUTION:
Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
C: DISASSEMBLY
1) Remove the boot ring.
G4M0370
2) Remove the piston boot.
G4M0474
3) Gradually supply compressed air via inlet of
caliper body to force piston out.
CAUTION:
IPlace a wooden block as shown in Figure to
prevent damage to piston.
IDo not apply excessively high-pressure.
G4M0371
4) Remove piston seal from caliper body cylinder.
G4M0388
5) Remove lock pin sleeve and boot from caliper
body.
6) Remove guide pin boot.
D: INSPECTION
1) Repair or replace faulty parts.
2) Check caliper body and piston for uneven wear,
damage or rust.
3) Check rubber parts for damage or deterioration.
E: ASSEMBLY
1) Clean caliper body interior using brake fluid.
2) Apply a coat of brake fluid to piston seal and fit
piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner
surface of cylinder and outer surface of piston.
4) Insert piston into cylinder.
CAUTION:
Do not force piston into cylinder.
5) Apply a coat of specified grease to boot and fit
in groove on ends of cylinder and piston.
Grease
NIGLUBE RX-2 (Part No. 003606000)
28
4-4[W2C0]SERVICE PROCEDURE
2. Rear Disc Brake