Subaru Legacy IV (2008 year). Service manual - part 952

BR-20

Rear Disc Rotor

BRAKE

6. Rear Disc Rotor

A: REMOVAL

1) Lift up the vehicle, then remove the rear wheels.
2) Release the parking brake.
3) Remove the two mounting bolts, and remove the
disc brake assembly.

4) Suspend the disc brake assembly so that the
hose is not stretched.
5) Remove the disc rotor.

NOTE:
If it is difficult to remove the disc rotor, perform the
following two methods in order.

(1) Turn the adjusting screw using a flat tip
screwdriver until the brake shoe is far enough
away to allow removal of the disc rotor.

(2) If it is difficult to remove the disc rotor from
the hub, drive an 8 mm bolt into the threads B of
the rotor, then remove the rotor.

B: INSTALLATION

1) Install in the reverse order of removal.
2) Adjust the parking brake. <Ref. to PB-8, AD-
JUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>

(1) Adjusting screw

(2) Cover

(3) Flat tip screwdriver

(4) Back plate

BR-00346

(1)

(4)

(2)

(3)

BR-00155

A

B

BR-00036

BR-21

Rear Disc Rotor

BRAKE

C: INSPECTION

1) Check the rear wheel bearing play and axle hub
runout before inspecting the disc rotor runout limit.
<Ref. to DS-21, INSPECTION, Rear Hub Unit
Bearing.>
2) Secure the disc rotor by tightening the five wheel
nuts.
3) Set a dial gauge 10 mm (0.39 in) inward from the
disc rotor outer circumference. Rotate the disc rotor
to check runout. If the disc rotor runout exceeds the
limit, resurface the disc rotor. After grinding, check
the thickness of the disc rotor according to the pro-
cedure in step 4).

Disc rotor runout limit:

0.05 mm (0.0020 in)

4) Set a micrometer 10 mm (0.39 in) inward from
the disc rotor outer perimeter, and then measure
the disc rotor thickness. If the thickness of the disc
rotor exceeds the service limit, replace with a new
disc rotor.

BR-00037

A

B

BR-00036

 

Standard

Limit

Disc outer dia.

Disc rotor thickness A

Solid disc

10 (0.39)

8.5 (0.335)

274 (10.79)

mm (in) Ventilated disc

18 (0.71)

16 (0.63)

290 (11.42)

BR-22

Rear Disc Brake Assembly

BRAKE

7. Rear Disc Brake Assembly

A: REMOVAL

CAUTION:
Do not allow brake fluid to come in contact with
vehicle body. If it does, wash off with water and
wipe away completely.
1) Lift up the vehicle, then remove the rear wheels.
2) Disconnect the brake hose from caliper body as-
sembly.
3) Remove the caliper lower bolt.

4) Raise the caliper body, and then move it toward
vehicle center to separate it from the support.
5) Remove the support from housing.

NOTE:
Remove the support only when replacing the rotor
or support. It is not necessary to remove it when
servicing the caliper body assembly.
6) Remove mud and foreign matter from the caliper
body assembly and the support.

CAUTION:
Be careful not to allow foreign matter to enter
the brake hose connector.

B: INSTALLATION

1) Apply a thin coat of Molykote M7439 (Part No.
K0777YA000) or grease contained in the pad kit to
the support.

2) Install the support to the housing.

Tightening torque:

66 N·m (6.7 kgf-m, 48.7 ft-lb)

3) Apply a thin coat of Molykote M7439 (Part No.
K0777YA000) or grease contained in the pad kit to
the pad clip.

4) Apply a thin coat of Molykote AS880N (Part No.
K0779YA010) or grease contained in the pad kit to
the contact surface between the pad and shim.
5) Install the pad to support.
6) Install the caliper body to the support.

Tightening torque:

Solid disc brake model

27 N·m (2.8 kgf-m, 19.9 ft-lb)

Ventilated disc brake model

37 N·m (3.7 kgf-m, 27.2 ft-lb)

7) Connect the brake hose using a new brake hose
gasket.

Tightening torque:

18 N·m (1.8 kgf-m, 13.0 ft-lb)

8) Bleed air from the brake system.

BR-00347

BR-00597

BR-00599

BR-23

Rear Disc Brake Assembly

BRAKE

C: DISASSEMBLY

1) Remove the piston boot.

2) Place a wooden block in the caliper body as
shown in the figure to prevent the piston from jump-
ing out and being damaged.
3) Gradually apply compressed air via the brake
hose installation hole to push the piston out.

4) Remove the piston seal from caliper body cylin-
der.

CAUTION:
Do not damage the cylinder and piston seal
groove.

5) Remove the lock pin sleeve and boot from cali-
per body.
6) Remove the guide pin boot.

D: ASSEMBLY

1) Clean the inside of the caliper body using brake
fluid.
2) Apply a coat of brake fluid to piston seal and in-
stall the piston seal to the caliper body groove.
3) Apply a coat of brake fluid to the inner surface of
cylinder and the entire outer surface of the piston.
4) Apply grease contained in the piston seal kit to
the boot, and install it to the groove at the end of the
cylinder.
5) Insert the piston into cylinder.

CAUTION:
Do not force the piston into cylinder.
6) Position the boot in the grooves on piston and
cylinder.

7) Apply grease contained in the piston seal kit to
the guide pin, outer periphery, sleeve periphery,
cylinder inner surface, and boot grooves.

8) Insert the guide pin boot to the support.
9) Install the lock pin boot to the support, and then
insert the lock pin sleeve into the specified position.

CAUTION:
Insert the lock pin and guide pin into position,
and make sure that they slide and seat properly.

(1) Place a wooden block of 30 mm (1.18 in) width.

BR-00041

(1)

BR-00042

BR-00043

(1) Piston

(2) Piston boot

(3) Caliper body

(4) Piston seal

(1) Pin boot

(2) Lock pin or guide pin

(3) Grease applied area

BR-00243

(1)

(2)

(3)

(4)

BR-00362

(1)

(2)

: (3)