SUBARU LEGACY 1995 Service Repair Manual

G4M0379
2) Raise caliper body.
3) Remove pad from support.
G4M0362
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)
CAUTION:

Always replace the pads for both the left and right
wheels at the same time. Also replace pad clips if they
are twisted or worn.

A 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.

Replace pad if there is oil or grease on it.
G4M0363
5) Apply thin coat of PBC GREASE (Part No. 03607000)
to the frictional portion between pad and pad clip.
6) Install pad on support.
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.
26
4-4SERVICE PROCEDURE
2. Rear Disc Brake

G4M0382
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.
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)
G4M0383
3) Measure disc rotor thickness.
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 Park-
ing Brake [W4A0].
G4M0384
B: REMOVAL
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.
3) Remove lock pin.
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).
27
4-4SERVICE PROCEDURE
2. Rear Disc Brake

G4M0370
C: DISASSEMBLY
1) Remove the boot ring.
G4M0474
2) Remove the piston boot.
G4M0371
3) Gradually supply compressed air via inlet of caliper
body to force piston out.
CAUTION:

Place a wooden block as shown in Figure to prevent
damage to piston.

Do not apply excessively high-pressure.
G4M0388
4) Remove piston seal from caliper body cylinder.
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, dam-
age or rust.
3) Check rubber parts for damage or deterioration.
28
4-4SERVICE PROCEDURE
2. Rear Disc Brake

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)
G4M0373
6) Install the piston boot to the caliper body, and attach
boot ring.
G4M0390
7) Apply a coat of specified grease to guide pin, outer
surface, sleeve outer surface, cylinder inner surface, and
boot grooves.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
8) Install guide pin boot on caliper body.
9) Install lock pin boot on caliper body and insert lock pin
sleeve into place.
G4M0375
29
4-4SERVICE PROCEDURE
2. Rear Disc Brake

F: INSTALLATION
1) Install disc rotor on hub.
2) Install support on back plate.
Tightening torque:
52±6 N⋅m (5.3±0.6 kg-m, 38.3±4.3 ft-lb)
CAUTION:

Always replace the pads for both the left and right
wheels at the same time. Also replace pad clips if they
are twisted or worn.

A 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.

Replace pads if there is oil or grease on them.
3) Apply thin coat of PBC GREASE (Part No. 003607000)
to the frictional portion between pad and pad clip.
G4M0363
4) Install pads on support.
5) Install caliper body on support.
Tightening torque:
20±4 N⋅m (2.0±0.4 kg-m, 14.5±2.9 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:

The brake hose must be connected without any
twist.

Replace brake hose gaskets with new ones.
7) Bleed air from brake system.
30
4-4SERVICE PROCEDURE
2. Rear Disc Brake

3. Rear Drum Brake
B4M0075A
1Air bleeder cap

2Air bleeder screw

3Boot

4Piston

5Cup

6Spring

7Wheel cylinder body

8Pin

9Plug

10Back plate
11Upper shoe return spring

12Retainer

13Washer

14Parking brake lever

15Brake shoe (Trailing)

16Brake shoe (Leading)

17Shoe hold-down spring

18Cup

19Adjusting lever

20Adjuster
21Lower shoe return spring

22Adjusting spring

23Plug
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 8±1 (0.8±0.1, 5.8±0.7)
T2: 10±2 (1.0±0.2, 7.2±1.4)
T3: 52±6 (5.3±0.6, 38.3±4.3)
31
4-4SERVICE PROCEDURE
3. Rear Drum Brake

G4M0393
A: REMOVAL
1. BRAKE DRUM AND SHOE
1) Loosen wheel nuts, jack-up vehicle, support it with rigid
racks, and remove wheel.
2) Release parking brake.
3) Remove brake drum from brake assembly.
G4M0242
NOTE:
If it is difficult to remove brake drum, remove adjusting hole
cover from back plate, and then, turn adjuster assembly
pawls using a slot-type screwdriver until brake shoe sepa-
rates from the drum.
G4M0395
4) Hold hold-down pin by securing rear of back plate with
your hand.
5) Disconnect hold-down cup from hold-down pin by rotat-
ing hold-down cup.
G4M0396
6) Disconnect lower shoe return spring from shoes.
G4M0397
7) Remove shoes one by one from back plate with
adjuster.
CAUTION:
Be careful not to bend parking brake cable excessively
when removing brake shoes.
8) Disconnect parking brake cable from parking lever.
32
4-4SERVICE PROCEDURE
3. Rear Drum Brake

G4M0398
9) Remove the following:

1Retainer

2Washer

3Parking lever

4Upper shoe return spring

5Trailing shoe

6Leading shoe

7Shoe hold-down spring

8Shoe hold-down cup

9Adjusting lever

10Adjusting spring

11Adjuster

12Lower shoe return spring
G4M0399
2. BRAKE ASSEMBLY
1) Remove wheel.
2) Remove axle nut.
3) Remove brake drum
4) Unscrew the brake pipe flare nut and disconnect brake
pipe.
5) Remove hub.
G4M0400
6) Remove the bolts installing back plate, and then,
remove brake assembly.
G4M0401
3. WHEEL CYLINDER
1) Remove brake drum and shoes.
2) Unscrew brake pipe flare nut; and disconnect brake
pipe.
3) Remove the bolts installing wheel cylinder on back
plate, and remove it.
33
4-4SERVICE PROCEDURE
3. Rear Drum Brake

G4M0402
B: DISASSEMBLY
1. WHEEL CYLINDER
1) Remove right and left dust boots from wheel cylinder.
2) Remove piston, cup, spring and air bleeder screw and
cap.

1Bleeder cap

2Bleeder screw

3Spring

4Cylinder

5Cup

6Piston

7Boot
G4M0403
C: INSPECTION
1) If the inside surface of brake drum is streaked, correct
the surface. And, if it is unevenly worn, taperingly streaked,
or the outside surface of brake drum is damaged, correct
or replace it.
2) Measure the drum inner diameter.
Drum inner diameter: “L”
Standard 228.6 mm (9 in)
Service limit 230.6 mm (9.08 in)
3) Measure the lining thickness.
Lining thickness:
Standard 4.1 mm (0.161 in)
Service limit 1.5 mm (0.059 in)
4) If the deformation or wear of back plate, shoe, etc. are
notable, replace them.
5) When the shoe return spring tension is excessively
weakened, replace it, taking care to identify upper and
lower springs.
34
4-4SERVICE PROCEDURE
3. Rear Drum Brake

D: ASSEMBLY
1. WHEEL CYLINDER
Clean all parts in brake fluid. Check and replace faulty
parts.

Cup and boot for damage or fatigue

Cylinder, piston and spring or damage or rust formation
1) Assembly is the reverse order of disassembly.
G4M0404
(1) When installing the cup, use ST, apply brake fluid
to the frictional surface for smooth installation and pay
attention to cup direction.
(2) STs are available in different sizes.
CAUTION:

When replacing the repair kit, make sure that the
sizes of cylinder and cup are the same as those which
were replaced.

Use only the tool of the correct size.
ST: ADAPTER
Applicable size Part No.
17.46 mm (11/16 in) 925460000
19.05 mm (3/4 in) 926460000
CAUTION:
While assembling, be careful to prevent any metal
chip, dust or dirt from entering the wheel cylinder.
G4M0405
2) Apply rubber grease to the boot inside as shown in
Figure.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
CAUTION:
Never use brake grease.
G4M0401
E: INSTALLATION
1. WHEEL CYLINDER
Install wheel cylinder on back plate, and tighten bolts.
Tightening torque:
10±2 N⋅m (1.0±0.2 kg-m, 7.2±1.4 ft-lb)
35
4-4SERVICE PROCEDURE
3. Rear Drum Brake