1999 SUBARU LEGACY Service Repair Manual

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

3) Remove C-ring with C-ring pliers.
B4M1448A
4) Gradually supply compressed air via inlet of
master cylinder to force piston out.
CAUTION:
IPiston may jump out from master cylinder.
IDo not apply excessively high-pressure.
B4M1449
CAUTION:
IDo not disassemble the piston assembly;
otherwise, the spring set value may be
changed.
IUse brake fluid or methanol to wash inside
wall of cylinder, pistons and piston cups. Be
careful not to damage parts when washing. If
methanol is used for washing, do not dip rub-
ber parts, such as piston cups, in it for more
than 30 seconds; otherwise, they may become
swelled.
3. DISASSEMBLING PROCEDURE
(OTHER MODELS)
1) Remove reserve tank.
2) Remove cylinder pin. (only vehicle equipped
with ABS)
S4M0123A
3) Pry up the pawl and remove the piston retainer.
NOTE:
Piston may jump out from master cylinder.
S4M0124
4) Extract primary piston assembly and secondary
piston assembly.
CAUTION:
IDo not disassemble the piston assembly;
otherwise, the spring set value may be
changed.
IUse brake fluid or methanol to wash inside
wall of cylinder, pistons and piston cups. Be
careful not to damage parts when washing. If
methanol is used for washing, do not dip rub-
ber parts, such as piston cups, in it for more
than 30 seconds; otherwise, they may become
swelled.
C: INSPECTION
If any damage, deformation, wear, swelling, rust,
and other faults are found on the primary piston
assembly, secondary piston assembly, supply
valve stopper, or gasket, replace the faulty part.
CAUTION:
IThe primary and secondary pistons must be
replaced as complete assemblies.
IThe service limit of the clearance between
each piston and the master cylinder inner dia.
is 0.11 mm (0.0043 in).
IWhen handling parts, be extremely careful
not to damage or scratch the parts, or let any
foreign matter get on them.
38
4-4[W5B3]SERVICE PROCEDURE
5. Master Cylinder

D: ASSEMBLY
1. PRECAUTIONS FOR ASSEMBLING
1) When assembling, be sure to use recom-
mended brake fluid.
2) Ensure that the inside wall of cylinder, pistons,
and piston cups are free from dirt when assem-
bling.
3) Be extremely careful not to damage, scratch, or
dent cylinder inside wall, pistons, and piston cups.
4) Do not drop parts. Never attempt to use any
part that has been dropped accidentally.
2. ASSEMBLING OPERATION (2200 cc
MODEL WITH ABS)
1) Assembling piston assembly:
Apply recommended brake fluid to inside wall of
cylinder, and to outer surface of piston assembly,
and install piston assemblies carefully into cylinder.
2) Assemble cylinder pin by pushing in primary
piston.
3) Assemble plate and guide assembly.
4) Assemble C-ring.
CAUTION:
After assembling, ensure that the C-ring is fit-
ted securely in the ring grove.
5) Install seal to reservoir tank.
B4M1450A
6) Install pin with drift pins which secures reservoir
tank to master cylinder.
3. ASSEMBLING OPERATION (OTHER
MODELS)
1) Assembling piston assembly:
Apply recommended brake fluid to inside wall of
cylinder, and to outer surface of piston assembly,
and install piston assemblies carefully into cylinder.
2) Assembling cylinder pin:3) Press the pawl and install the piston retainer
into the master cylinder.
S4M0124
E: INSTALLATION
To install the master cylinder to the body, reverse
the sequence of removal procedure.
Tightening torque:
Master cylinder mounting nut
14
±4 N´m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
Piping flare nut
15
+3/þ2N´m (1.5+0.3/þ0.2kg-m, 10.8+2.2/þ1.4ft-lb)
CAUTION:
Be sure to use recommended brake fluid.
39
[W5E0]4-4SERVICE PROCEDURE
5. Master Cylinder