1999 SUBARU LEGACY brake rotor

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

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)

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

14. ABS Sensor
A: REMOVAL
1. FRONT ABS SENSOR
1) Disconnect front ABS sensor connector located
in engine compartment.
2) Remove bolts which secure sensor harness to
strut.
B4M0079A
3) Remove bolts which secure sensor harness to
body.
B4M1181A
4) Remove bolts which secure front ABS sensor to
housing, and remove front ABS sensor.
CAUTION:
IBe careful not to damage pole piece located
at tip of the sensor and teeth faces during
removal.
IDo not pull sensor harness during removal.
B4M1183A
5) Remove front disc brake caliper and disc rotor
from housing after removing front tire.6) Remove front drive shaft and housing and hub
assembly.
7) Remove tone wheel while removing hub from
housing and hub assembly.
CAUTION:
Be careful not to damage teeth faces of tone
wheel during removal.
G4M0444
2. REAR ABS SENSOR
1) Remove rear seat and disconnect rear ABS
sensor connector.
2) Remove rear sensor harness bracket from rear
trailing link and bracket.
3) Remove rear ABS sensor from rear back plate.
B4M1182A
4) Remove rear tone wheel while removing hub
from housing and hub assembly. [W2A0].>
CAUTION:
IBe careful not to damage pole piece located
at tip of the sensor and teeth faces during
removal.
IDo not pull sensor harness during removal.
B: INSPECTION
1. ABS SENSOR
1) Check pole piece of ABS sensor for foreign par-
ticles or damage. If necessary, clean pole piece or
replace ABS sensor.
52
4-4[W14A1]SERVICE PROCEDURE
14. ABS Sensor

E: INSTALLATION
1) Install ABSCM&H/U.
CAUTION:
Confirm that the specifications of the
ABSCM&H/U conforms to the vehicle specifica-
tions.
Tightening torque:
18
±5 N´m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B4M1222
2) Connect brake pipes to their correct
ABSCM&H/U connections.
Brake pipe tightening torque:
15+3/þ2N´m (1.5+0.3/þ0.2kg-m, 10.8+2.2/þ1.4ft-lb)
3) Using cable clip, secure ABSCM&H/U harness
to bracket.
4) Connect connector to ABSCM&H/U.
CAUTION:
IBe sure to remove all foreign matter from
inside the connector before connecting.
IEnsure that the ABSCM&H/U connetor is
securely locked.
5) Install air intake duct.
6) Connect ground cable to battery.
7) Bleed air from the brake system.
16. G Sensor
A: REMOVAL
1. FRONT ABS SENSOR
1) Disconnect front ABS sensor connector located
in engine compartment.
2) Remove bolts which secure sensor harness to
strut.
B4M1442A
3) Remove bolts which secure sensor harness to
body.
B4M1181A
4) Remove bolts which secure front ABS sensor to
housing, and remove front ABS sensor.
CAUTION:
IBe careful not to damage pole piece located
at tip of the sensor and teeth faces during
removal.
IDo not pull sensor harness during removal.
B4M1183A
5) Remove front disc brake caliper and disc rotor
from housing after removing front tire.
60
4-4[W15E0]SERVICE PROCEDURE
16. G Sensor

E: INSTALLATION
1) Install ABSCM&H/U.
CAUTION:
Confirm that the specifications of the
ABSCM&H/U conforms to the vehicle specifica-
tions.
Tightening torque:
18
±5 N´m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B4M1222
2) Connect brake pipes to their correct
ABSCM&H/U connections.
Brake pipe tightening torque:
15+3/þ2N´m (1.5+0.3/þ0.2kg-m, 10.8+2.2/þ1.4ft-lb)
3) Using cable clip, secure ABSCM&H/U harness
to bracket.
4) Connect connector to ABSCM&H/U.
CAUTION:
IBe sure to remove all foreign matter from
inside the connector before connecting.
IEnsure that the ABSCM&H/U connetor is
securely locked.
5) Install air intake duct.
6) Connect ground cable to battery.
7) Bleed air from the brake system.
16. G Sensor
A: REMOVAL
1. FRONT ABS SENSOR
1) Disconnect front ABS sensor connector located
in engine compartment.
2) Remove bolts which secure sensor harness to
strut.
B4M1442A
3) Remove bolts which secure sensor harness to
body.
B4M1181A
4) Remove bolts which secure front ABS sensor to
housing, and remove front ABS sensor.
CAUTION:
IBe careful not to damage pole piece located
at tip of the sensor and teeth faces during
removal.
IDo not pull sensor harness during removal.
B4M1183A
5) Remove front disc brake caliper and disc rotor
from housing after removing front tire.
60
4-4[W15E0]SERVICE PROCEDURE
16. G Sensor