SUBARU LEGACY 1999 Service Repair Manual

6) Install the piston boot to the caliper body, and
attach boot ring.
G4M0373
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)
G4M0390
G4M0375
8) Install guide pin boot on caliper body.
9) Install lock pin boot on caliper body and insert
lock pin sleeve into place.
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:
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 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.
4) Install pads on support.
G4M0363
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:
IThe brake hose must be connected without
any twist.
IReplace brake hose gaskets with new ones.
7) Bleed air from brake system.
29
[W2F0]4-4SERVICE PROCEDURE
2. Rear Disc Brake

3. Rear Drum Brake
A: REMOVAL
B4M0075B
(1) Air bleeder cap
(2) Air bleeder screw
(3) Boot
(4) Piston
(5) Cup
(6) Spring
(7) Wheel cylinder body
(8) Pin
(9) Plug
(10) Back plate(11) Upper shoe return spring
(12) Retainer
(13) Washer
(14) Parking brake lever
(15) Brake shoe (Trailing)
(16) Brake shoe (Leading)
(17) Shoe hold-down spring
(18) Cup
(19) Adjusting lever
(20) Adjuster(21) Lower shoe return spring
(22) Adjusting spring
(23) Plug
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)
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.
G4M0393
30
4-4[W3A0]SERVICE PROCEDURE
3. Rear Drum Brake

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 separates from the
drum.
G4M0242
4) Hold hold-down pin by securing rear of back
plate with your hand.
G4M0395
5) Disconnect hold-down cup from hold-down pin
by rotating hold-down cup.
6) Disconnect lower shoe return spring from
shoes.
G4M0396
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.
G4M0397
8) Disconnect parking brake cable from parking
lever.
9) Remove the following:
B4M1125A
(1) Retainer
(2) Washer
(3) Parking lever
(4) Upper shoe return spring
(5) Trailing shoe
(6) Leading shoe
(7) Shoe hold-down spring
(8) Shoe hold-down cup
(9) Adjusting lever
(10) Adjusting spring
(11) Adjuster
(12) Lower shoe return spring
2. BRAKE ASSEMBLY
1) Remove wheel.
2) Remove axle nut.
3) Remove brake drum
31
[W3A2]4-4SERVICE PROCEDURE
3. Rear Drum Brake

4) Unscrew the brake pipe flare nut and discon-
nect brake pipe.
G4M0399
5) Remove hub.
6) Remove the bolts installing back plate, and
then, remove brake assembly.
G4M0400
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.
G4M0401
B: DISASSEMBLY
1. WHEEL CYLINDER
1) Remove right and left dust boots from wheel
cylinder.
B4M1126A
2) Remove piston, cup, spring and air bleeder
screw and cap.
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: ªLº
Standard
228.6 mm (9 in)
Service limit
230.6 mm (9.08 in)
G4M0403
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 exces-
sively weakened, replace it, taking care to identify
upper and lower springs.
32
4-4[W3A3]SERVICE PROCEDURE
3. Rear Drum Brake

D: ASSEMBLY
1. WHEEL CYLINDER
1) Clean all parts in brake fluid. Check and replace
faulty parts.
ICup and boot for damage or fatigue
ICylinder, piston and spring or damage or rust
formation
2) Assembly is the reverse order of disassembly.
(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:
IWhen replacing the repair kit, make sure that
the sizes of cylinder and cup are the same as
those which were replaced.
IUse 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.
G4M0404
3) Apply rubber grease to the boot inside as
shown in Figure.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
CAUTION:
Never use brake grease.
G4M0405
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)
G4M0401
2. BRAKE DRUM AND SHOE
1) Clean back plate and wheel cylinder.
33
[W3E2]4-4SERVICE PROCEDURE
3. Rear Drum Brake

2) Apply grease to portions indicated by arrows in
Figure.
Brake grease:
Dow Corning Molykote No. 7439 (Part No.
725191460)
G4M0407
3) Apply grease to adjusting screw and both ends
of adjuster.
Brake grease:
Dow Corning Molykote No. 7439 (Part No.
725191460)
G4M0408
4) Connect upper shoe return spring to shoes.
5) While positioning shoes (one at a time) in
groove on wheel cylinder, secure shoes.
G4M0409
6) Connect lower shoe return spring.
7) Fix shoes by connecting hold-down cup to hold-
down pin.
3. BRAKE ASSEMBLY
1) Install brake assembly on housing, and tighten
bolts to install back plate.
Tightening torque:
52
±6 N´m (5.3±0.6 kg-m, 38.3±4.3 ft-lb)
G4M0400
2) Install hub.
3) Connect brake pipe, and tighten brake pipe
flange nut.
Tightening torque:
15+3/þ2N´m (1.5+0.3/þ0.2kg-m, 10.8+2.2/þ1.4ft-lb)
4) Set the outside diameter of brake shoes less
than 0.5 to 0.8 mm (0.020 to 0.031 in) in compari-
son with the inside diameter of brake drum.
5) Install brake drum.
6) After installing brake assembly, bleed air from
brake line.
34
4-4[W3E3]SERVICE PROCEDURE
3. Rear Drum Brake

4. Parking Brake (Rear Disc Brake)
A: REMOVAL
B4M1127A
(1) Back plate
(2) Retainer
(3) Spring washer
(4) Lever
(5) Parking brake shoe (Primary)
(6) Parking brake show (Secondary)
(7) Strut spring(8) Strut
(9) Shoe guide plate
(10) Primary return spring
(11) Secondary return spring
(12) Adjusting spring
(13) Adjuster
(14) Shoe hold-down cup(15) Shoe hold down spring
(16) Shoe hold down pin
(17) Adjusting hole cover
Tightening torque: N´m(kg-m, ft-lb)
T:
52±6 (5.3±0.6, 38.3±4.3)
1) Remove the two mounting bolts to the disc
brake assembly and remove the disc brake assem-
bly.
G4M0412
2) Suspend the disc brake assembly so that the
hose is not stretched.
3) Remove the disc rotor.4) Remove shoe return spring from parking brake
assembly.
5) Remove front shoe hold down spring and pin
with pliers.
6) Remove strut and strut spring.
7) Remove adjuster assembly from parking brake
assembly.
8) Remove brake shoe.
9) Remove rear shoe hold-down spring and pin
with pliers.
35
[W4A0]4-4SERVICE PROCEDURE
4. Parking Brake (Rear Disc Brake)

10) Remove parking cable from parking lever.
G4M0413
11) Using a standard screwdriver, raise retainer.
Remove parking lever and washer from brake
shoe.
B: INSPECTION
1) Measure brake disc inside diameter. If the disc
is scored or worn, replace the brake disc.
Disc inside diameter:
Standard
170 mm (6.69 in)
Service limit
171 mm (6.73 in)
2) Measure the lining thickness. If it exceeds the
limit, replace shoe assembly.
Lining thickness:
Standard
3.2 mm (0.126 in)
Service limit
1.5 mm (0.059 in)
CAUTION:
Replace the brake shoes on the right and left
brake assembly at the same time.
C: INSTALLATION
CAUTION:
Be sure lining surface is free from oil contami-
nation.
Brake grease:
Dow Corning Molykote No 7439 (Part No.
725191460)
1) Apply brake grease to the following places.
ISix contact surfaces of shoe rim and back plate
packing
IContact surface of shoe wave and anchor pin
IContact surface of lever and strut
IContact surface of shoe wave and adjuster
assembly
IContact surface of shoe wave and strut
IContact surface of lever and shoe wave
2) Installation is in reverse order of removal.CAUTION:
IUse new retainers and clinch them when
installing brake shoes to levers.
IEnsure that parking lever moves smoothly.
IDo not confuse left parking lever with right
one.
IDo not confuse left strut with right one.
NOTE:
Ensure that adjuster assembly is securely installed
with screw in the left side, facing vehicle front.
G4M0414
NOTE:
Ensure that shoe return spring is installed as
shown in Figure.
G4M0415
3) Adjust parking brakes.
CAUTION:
After replacing parking brake lining, be sure to
drive vehicle for ªbreak-inº purposes.
(1) Drive the vehicle about 35 km/h (22 MPH).
(2) With the parking brake release button
pushed in, pull the parking brake lever gently,
pulling with a force of approximately 147 N (15
kg, 33 lb).
(3) Drive the vehicle for about 200 m (0.12 mile)
in this condition.
(4) Wait 5 to 10 minutes for the parking brake
to cool down. Repeat this procedure once
more.
(5) After breaking-in, re-adjust parking brakes.
36
4-4[W4B0]SERVICE PROCEDURE
4. Parking Brake (Rear Disc Brake)

D: ADJUSTMENT
1. SHOE CLEARANCE
1) Remove adjusting hole cover from back plate.
2) Turn adjusting screw using a slot-type screw-
driver until brake shoe is in close contact with disc
rotor.
G4M0416
3) Turn back (downward) adjusting screw 3 or 4
notches.
4) Install adjusting hole cover to back plate.
2. LEVER STROKE
1) Remove console box lid.
2) Forcibly pull parking brake lever 3 to 5 times.
3) Adjust parking brake lever by turning adjusting
nut until parking brake lever stroke is set at 7 to 8
notches with operating force of 196 N (20 kg, 44
lb).
B4M0050A
4) Tighten lock nut.
5) Install console box lid.
Lever stroke:
7 to 8 notches when pulled with a force
of 196 N (20 kg, 44 lb)
Tightening torque (Lock nut):
5.9
±1.5 N´m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
5. Master Cylinder
A: REMOVAL
1) Thoroughly drain brake fluid from reservoir
tank.
2) Disconnect fluid level indicator harness connec-
tor.
3) Remove brake pipes from master cylinder.
4) Remove master cylinder mounting nuts, and
take out master cylinder from brake booster.
CAUTION:
Be extremely careful not to spill brake fluid.
Brake fluid spilt on the vehicle body will harm
the painted surface; wipe it off quickly if spilt.
B: DISASSEMBLY
1. PRECAUTIONS FOR DISASSEMBLING
1) Remove mud and dirt from the surface of brake
master cylinder.
2) Prepare tools necessary for disassembly
operation, and arrange them neatly on work bench.
3) Clean work bench.
2. DISASSEMBLING PROCEDURE (2200
cc MODEL WITH ABS)
1) Remove pin with drift pin which secures reserve
tank to master cylinder.
B4M1446A
2) Remove cylinder pin with magnetic pick-up tool
while pushing in primary piston.
B4M1447A
37
[W5B2]4-4SERVICE PROCEDURE
5. Master Cylinder

D: ADJUSTMENT
1. SHOE CLEARANCE
1) Remove adjusting hole cover from back plate.
2) Turn adjusting screw using a slot-type screw-
driver until brake shoe is in close contact with disc
rotor.
G4M0416
3) Turn back (downward) adjusting screw 3 or 4
notches.
4) Install adjusting hole cover to back plate.
2. LEVER STROKE
1) Remove console box lid.
2) Forcibly pull parking brake lever 3 to 5 times.
3) Adjust parking brake lever by turning adjusting
nut until parking brake lever stroke is set at 7 to 8
notches with operating force of 196 N (20 kg, 44
lb).
B4M0050A
4) Tighten lock nut.
5) Install console box lid.
Lever stroke:
7 to 8 notches when pulled with a force
of 196 N (20 kg, 44 lb)
Tightening torque (Lock nut):
5.9
±1.5 N´m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
5. Master Cylinder
A: REMOVAL
1) Thoroughly drain brake fluid from reservoir
tank.
2) Disconnect fluid level indicator harness connec-
tor.
3) Remove brake pipes from master cylinder.
4) Remove master cylinder mounting nuts, and
take out master cylinder from brake booster.
CAUTION:
Be extremely careful not to spill brake fluid.
Brake fluid spilt on the vehicle body will harm
the painted surface; wipe it off quickly if spilt.
B: DISASSEMBLY
1. PRECAUTIONS FOR DISASSEMBLING
1) Remove mud and dirt from the surface of brake
master cylinder.
2) Prepare tools necessary for disassembly
operation, and arrange them neatly on work bench.
3) Clean work bench.
2. DISASSEMBLING PROCEDURE (2200
cc MODEL WITH ABS)
1) Remove pin with drift pin which secures reserve
tank to master cylinder.
B4M1446A
2) Remove cylinder pin with magnetic pick-up tool
while pushing in primary piston.
B4M1447A
37
[W5B2]4-4SERVICE PROCEDURE
5. Master Cylinder