1997 SUBARU LEGACY service

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)
27
4-4SERVICE PROCEDURE
1. Front Disc Brake

B4M1167
A: ON-CAR SERVICE
1. PAD
1) Remove lock pin.
2) Raise caliper body.
3) Remove pad.
B4M1168A
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.
B4M1169A
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)
28
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)
B4M1170
B: REMOVAL
1) Remove union bolt and disconnect brake hose from
caliper body assembly.
B4M1171
2) Remove bolt securing lock pin to caliper body.
3) Raise caliper body and move it toward vehicle center to
separate it from support.
B4M1192A
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.
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.
29
4-4SERVICE PROCEDURE
1. Front Disc Brake

C: DISASSEMBLY
1. EXCEPT 2500 cc MODEL
B4M1152B
1Caliper body

2Air bleeder screw

3Guide pin (Green)

4Pin boot

5Piston seal

6Piston

7Piston boot

8Lock pin (Yellow)
9Support

10Pad clip

11Outer shim

12Inner shim

13Pad (Outside)

14Pad (Inside)

15Disc rotor

16Disc 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)
30
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).
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