SUBARU LEGACY 1997 Service Repair Manual

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).
B4M1174A
2) 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.

Do not apply excessively high-pressure.
3) Remove piston boot.
B4M1173A
4) Remove piston seal from caliper body cylinder.
5) Remove guide pin and boot from caliper body.
31
4-4SERVICE PROCEDURE
1. Front Disc Brake

2. 2500 cc MODEL
B4M1151B
1Caliper body

2Air bleeder screw

3Guide pin (Green)

4Pin boot

5Piston seal

6Piston

7Piston boot

8Boot ring

9Lock pin (Yellow)
10Support

11Pad clip

12Outer shim

13Inner shim

14Pad (Outside)

15Pad (Inside)

16Disc rotor

17Disc 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)
32
4-4SERVICE PROCEDURE
1. Front Disc Brake

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).
B4M1164A
2) Using a standard screwdriver, remove boot ring from
piston.
3) Remove boot from piston end.
B4M1165A
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.
B4M1172A
5) Remove piston seal from caliper body cylinder.
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, dam-
age or rust.
3) Check rubber parts for damage or deterioration.
33
4-4SERVICE PROCEDURE
1. Front Disc Brake

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)
B4M1175A
5) Insert piston into cylinder.
CAUTION:
Do not force piston into cylinder.
B4M0072A
6) Position boot in grooves on cylinder and piston.
B4M1176A
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)
8) Install lock and guide pin boot on support.
34
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.
B4M0771A
4) Insert piston into cylinder.
CAUTION:
Do not force piston into cylinder.
G4M0373
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.
6) Position boot in grooves on cylinder and piston.
7) Install boot ring. Be careful not scratch boot.
B4M1176A
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)
9) Install lock pin boot and guide pin boot on support.
35
4-4SERVICE PROCEDURE
1. Front Disc Brake

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:

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.

When replacing the pad, replace pads of the right
and left wheels at the same time.
B4M1169A
3) Apply thin coat of PBC GREASE (Part No. 003607000)
to the frictional portion between pad and pad clip.
4) Install pads, rubber coated shim and stainless shim on
support.
5) Install caliper body on support.
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.
36
4-4SERVICE PROCEDURE
1. Front Disc Brake

2. Rear Disc Brake
G4M0912
1Guide pin

2Lock pin

3Lock pin boot

4Lock pin sleeve

5Air bleeder screw

6Guide pin boot

7Caliper body

8Piston seal

9Piston
10Piston boot

11Boot ring

12Pad clip

13Shim

14Inner shim

15Inner pad

16Outer pad

17Support

18Outer shim
19Disc 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)
G4M0378
A: ON-CAR SERVICE
1. PAD
1) Remove lock pin.
37
4-4SERVICE PROCEDURE
2. Rear Disc Brake

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.
38
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 4-4 [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).
39
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.
40
4-4SERVICE PROCEDURE
2. Rear Disc Brake