1996 SUBARU LEGACY brake rotor

2. 2500 cc AND OUTBACK (STEP ROOF) MODEL
G4M0990
1Lock pin

2Lock pin sleeve

3Lock pin boot

4Caliper body

5Air bleeder screw

6Guide pin

7Guide pin boot

8Piston seal

9Piston
10Piston boot

11Boot ring

12Support

13Pad clip

14Outer shim

15Pad (Outside)

16Pad (Inside)

17Inner shim

18Shim
19Disc rotor

20Disc 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: 36±5 (3.7±0.5, 26.8±3.6)
T4: 49±5 (5.0±0.5, 36.2±3.6)
T5: 78±10 (8.0±1.0, 58±7)
10
4-4COMPONENT PARTS
1. Front Disc Brake

2. Rear Disc Brake
B4M0066A
1Lock pin

2Lock pin sleeve

3Lock pin boot

4Air bleeder screw

5Caliper body

6Guide pin

7Guide pin boot

8Piston seal

9Piston

10Piston boot

11Boot ring

12Support

13Shim

14Inner shim

15Inner pad
16Pad clip

17Outer pad

18Outer shim

19Shoe hold-down pin

20Cover

21Back plate

22Retainer

23Spring washer

24Parking brake lever

25Parking brake shoe
(Secondary)

26Parking brake shoe
(Primary)

27Adjusting spring

28Strut
29Strut shoe spring

30Shoe guide plate

31Secondary shoe return spring

32Primary shoe return spring

33Adjuster

34Shoe hold-down cup

35Shoe hold-down spring

36Disc 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)
11
4-4COMPONENT PARTS
2. Rear Disc Brake

1. Front Disc Brake
B4M0065B
1Air bleeder screw

2Guide pin

3Guide pin boot

4Piston

5Piston seal

6Piston boot

7Lock pin boot

8Lock pin sleeve

9Caliper body
10Lock pin

11Housing

12Support

13Pad clip

14Outer shim

15Outer pad

16Inner pad

17Inner shim

18Shim
19Disc rotor

20Disc 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: 39±5 (4±0.5, 28.9±3.6)
T4: 78±10 (8.0±1.0, 58±7)
24
4-4SERVICE PROCEDURE
1. Front Disc Brake

G4M0361
A: ON-CAR SERVICE
1. PAD
1) Remove lock pin.
2) Raise caliper body.
3) Remove pad.
G4M0362
4) Check pad thickness A.
Pad thickness
(including back metal)
mm (in)Standard value 17 (0.67)
Wear limit 7.5 (0.295)
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. 003607000)
to the frictional portion between pad and pad clip.
6) Install pads on support.
7) Install caliper body on support.
NOTE:
If it is difficult to push piston during pad replacement,
loosen air bleeder to facilitate work.
G4M0364
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:
0.075 mm (0.0030 in)
25
4-4SERVICE PROCEDURE
1. Front Disc Brake

G4M0365
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
mm (in)Standard
valueService
limitDisc outer dia.
24.0
(0.945)22.0
(0.866)260
(10.24)
G4M0503
B: REMOVAL
1) Remove union bolt and disconnect brake hose from
caliper body assembly.
G4M0366
2) Loosen lock pin.
G4M0367
3) Raise caliper body and move it toward vehicle center to
separate it from support.
G4M0368
4) Remove support from housing.
NOTE:
Remove support only when replacing it or the rotor. It need
not be removed when servicing caliper body assembly.
26
4-4SERVICE PROCEDURE
1. Front Disc Brake

G4M0365
5) Remove disc rotor from hub.
NOTE:
If disc rotor seizes up within hub, drive disc rotor out by
installing an 8-mm bolt in holes B on the rotor.
6) Clean mud and foreign particles from caliper body
assembly and support.
C: DISASSEMBLY
1. EXCEPT 2500 cc AND OUTBACK (STEP ROOF)
MODEL
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).
G4M0371
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.
4) Remove piston seal from caliper body cylinder.
5) Remove lock pin sleeve and boot from caliper body.
6) Remove guide pin boot.
2. 2500 cc AND OUTBACK (STEP ROOF) MODEL
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).
B4M0769A
2) Using a standard screwdriver, remove boot ring from
piston.
3) Remove boot from piston end.
27
4-4SERVICE PROCEDURE
1. Front Disc Brake

G4M0363
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.
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.
31
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.
32
4-4SERVICE PROCEDURE
2. Rear Disc Brake