1999 SUBARU LEGACY brake rotor

2. Rear Disc Brake
B4M0066B
(1) Lock pin
(2) Lock pin sleeve
(3) Lock pin boot
(4) Air bleeder screw
(5) Caliper body
(6) Guide pin
(7) Guide pin boot
(8) Piston seal
(9) Piston
(10) Piston boot
(11) Boot ring
(12) Support
(13) Shim
(14) Inner shim
(15) Inner pad(16) Pad clip
(17) Outer pad
(18) Outer shim
(19) Shoe hold-down pin
(20) Cover
(21) Back plate
(22) Retainer
(23) Spring washer
(24) Parking brake lever
(25) Parking brake shoe (Secondary)
(26) Parking brake shoe (Primary)
(27) Adjusting spring
(28) Strut
(29) Strut shoe spring
(30) Shoe guide plate(31) Secondary shoe return spring
(32) Primary shoe return spring
(33) Adjuster
(34) Shoe hold-down cup
(35) Shoe hold-down spring
(36) 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)
8
4-4[C200]COMPONENT PARTS
2. Rear Disc Brake

1. Front Disc Brake
A: ON-CAR SERVICE
1. PAD
1) Remove lock pin.
2) Raise caliper body.
3) Remove pad.
B4M1167
4) Check pad thickness A.
B4M1168A
Pad thickness
(including back metal)
mm (in)Standard value 17 (0.67)
Wear limit 7.5 (0.295)
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.
003607000) to the frictional portion between pad
and pad clip.
B4M1169A
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.
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.
G4M0364
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)
18
4-4[W1A1]SERVICE PROCEDURE
1. Front Disc Brake

3) Measure disc rotor thickness.
G4M0365
NOTE:
Make sure that micrometer is set 5 mm (0.20 in)
inward of rotor outer perimeter.
Disc rotor thick-
ness A
mm (in)Standard value Service limit
24.0
(0.945)22.0
(0.866)
B: REMOVAL
1) Remove union bolt and disconnect brake hose
from caliper body assembly.
B4M1170
2) Remove bolt securing lock pin to caliper body.
B4M1171
3) Raise caliper body and move it toward vehicle
center to separate it from support.
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.
B4M1192A
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.
G4M0365
6) Clean mud and foreign particles from caliper
body assembly and support.
19
[W1B0]4-4SERVICE PROCEDURE
1. Front Disc Brake

C: DISASSEMBLY
1. EXCEPT 2500 cc MODEL
B4M1152D
(1) Caliper body
(2) Air bleeder screw
(3) Guide pin (Green)
(4) Pin boot
(5) Piston seal
(6) Piston
(7) Piston boot
(8) Lock pin (Yellow)(9) Support
(10) Pad clip
(11) Outer shim
(12) Inner shim
(13) Pad (Outside)
(14) Pad (Inside)
(15) Disc rotor
(16) Disc coverTightening 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)
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).
20
4-4[W1C1]SERVICE PROCEDURE
1. Front Disc Brake

2. 2500 cc MODEL
B4M1151D
(1) Caliper body
(2) Air bleeder screw
(3) Guide pin (Green)
(4) Pin boot
(5) Piston seal
(6) Piston
(7) Piston boot
(8) Boot ring(9) Lock pin (Yellow)
(10) Support
(11) Pad clip
(12) Outer shim
(13) Inner shim
(14) Pad (Outside)
(15) Pad (Inside)
(16) Disc rotor(17) Disc 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)
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).
22
4-4[W1C2]SERVICE PROCEDURE
1. Front Disc Brake

2. 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) Insert piston into cylinder.
CAUTION:
Do not force piston into cylinder.
B4M0771A
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)
To facilitate installation, fit boot starting with piston
end.
G4M0373
6) Position boot in grooves on cylinder and piston.
7) Install boot ring. Be careful not scratch boot.8) 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)
B4M1176A
9) Install lock pin boot and guide pin boot on sup-
port.
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:
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.
IWhen 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.
B4M1169A
4) Install pads, rubber coated shim and stainless
shim on support.
5) Install caliper body on support.
24
4-4[W1E2]SERVICE PROCEDURE
1. Front 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.
26
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.
27
[W2B0]4-4SERVICE PROCEDURE
2. Rear Disc Brake