1999 SUBARU LEGACY Service Repair Manual

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.
2. Rear Disc Brake
A: ON-CAR SERVICE
1. PAD
1) Remove lock pin.
G4M0378
2) Raise caliper body.
3) Remove pad from support.
G4M0379
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[W2A1]4-4SERVICE PROCEDURE
2. Rear Disc Brake

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)
G4M0362
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 pad if there is oil or grease on it.
5) Apply thin coat of PBC GREASE (Part No.
03607000) to the frictional portion between pad
and pad clip.
6) Install pad on support.
G4M0363
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.
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.
G4M0382
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)
3) Measure disc rotor thickness.
G4M0383
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 Parking Brake.
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4-4[W2A2]SERVICE PROCEDURE
2. Rear Disc Brake

B: REMOVAL
B4M1124A
(1) Guide pin
(2) Lock pin
(3) Lock pin boot
(4) Lock pin sleeve
(5) Air bleeder screw
(6) Guide pin boot
(7) Caliper body
(8) Piston seal
(9) Piston(10) Piston boot
(11) Boot ring
(12) Pad clip
(13) Shim
(14) Inner shim
(15) Inner pad
(16) Outer pad
(17) Support
(18) Outer shim(19) Disc 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)
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.
G4M0384
3) Remove lock pin.
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[W2B0]4-4SERVICE PROCEDURE
2. Rear Disc Brake

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).
C: DISASSEMBLY
1) Remove the boot ring.
G4M0370
2) Remove the piston boot.
G4M0474
3) Gradually supply compressed air via inlet of
caliper body to force piston out.
CAUTION:
IPlace a wooden block as shown in Figure to
prevent damage to piston.
IDo not apply excessively high-pressure.
G4M0371
4) Remove piston seal from caliper body cylinder.
G4M0388
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,
damage or rust.
3) Check rubber parts for damage or deterioration.
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)
28
4-4[W2C0]SERVICE PROCEDURE
2. Rear Disc Brake

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
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[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