Subaru Legacy (2005 year). Manual - part 823

BR-21

BRAKE

Front Disc Brake Assembly

4) Apply a thin coat of Molykote AS880N (Part No.
K0777YA010) to the three frictional portions be-
tween inner shim and outer shim of outer pads.

5) Install the pad on support.
6) Install the caliper body on support.

Tightening torque:

27 N

⋅

m (2.8 kgf-m, 19.9 ft-lb)

7) Connect the brake hose using new brake hose
gaskets.

Tightening torque:

18 N

⋅

m (1.8 kgf-m, 13.0 ft-lb)

8) Bleed air from the brake system.

2. 16-INCH TYPE

Refer to 15-inch type. <Ref. to BR-20, 15-INCH
TYPE, INSTALLATION, Front Disc Brake Assem-
bly.>

3. 17-INCH TYPE

1) Install the support on housing.

Tightening torque:

80 N

⋅

m (8.2 kgf-m, 59 ft-lb)

2) Apply a thin coat of Molykote M7439 to pad clip.

3) Apply a thin coat of Molykote AS880N (Part No.
K0777YA010) to the frictional portion between pad
and inner shim.

4) Apply a thin coat of Molykote AS880N (Part No.
K0779YA010) to the three frictional portions be-
tween inner shim and outer shim of outer pads.

BR-00341

BR-00340

BR-00238

BR-00341

BR-22

BRAKE

Front Disc Brake Assembly

5) Install the pad on support.

NOTE:
Install the pad indicator in proper direction.

CAUTION:
• Be sure to install so that the direction of pad
return spring faces to the input side of brake ro-
tor rotation direction as shown in the figure.
• Correctly install the pad return spring to sup-
porting surface of pad clip as shown in the fig-
ure.

• When the pad return spring is deformed or
damaged, replace the brake pad with new one.

6) Install the caliper body on support.
7) Connect the brake hose using new brake hose
gaskets.

Tightening torque:

18 N

⋅

m (1.8 kgf-m, 13.0 ft-lb)

8) Bleed air from the brake system.

C: DISASSEMBLY

1. 15-INCH TYPE

1) Clean mud and foreign particles from the caliper
body assembly and the support.

CAUTION:
Be careful not to allow foreign particles to enter 
the brake hose connector.
2) Place a wooden block in caliper body as shown
in the figure to prevent the piston from jumping out
and avoid being damaged.
3) Gradually supply compressed air via installation
hole of brake hose to force the piston out.

(1) LH 

− IN

(2) LH 

− OUT

(3) RH 

− IN

(4) RH 

− OUT

(5) Pad indicator

(6) Pad return spring

BR-00342

(5)

(6)

(6)

(1)

(2)

(3)

(4)

(5)

(6)

(6)

(1) Pad return spring

(2) Supporting surface of pad clip

(3) Brake rotor rotation direction

(1) Place a 30 mm (1.18 in) wide wood block here.

BR-00483

(1)

(2)

(3)

(1)

BR-00026

BR-23

BRAKE

Front Disc Brake Assembly

4) Remove the piston boot.

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

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

6) Remove the guide pin and boot from caliper
body.

2. 16-INCH TYPE

Refer to 15-inch type. <Ref. to BR-22, 15-INCH
TYPE, DISASSEMBLY, Front Disc Brake Assem-
bly.>

3. 17-INCH TYPE

Refer to 15-inch type. <Ref. to BR-22, 15-INCH
TYPE, DISASSEMBLY, Front Disc Brake Assem-
bly.>

D: ASSEMBLY

1. 15-INCH TYPE

1) Clean the caliper body interior using brake fluid.
2) Apply a coat of brake fluid to the piston seal and
fit piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner sur-
face of cylinder and outer surface of piston.
4) Apply a coat of specified grease to the boot and
fit in to the groove on ends of cylinder.

Grease:

NIGLUBE RX-2 (Part No. K0779GA102)

5) Insert the piston into cylinder.

CAUTION:
Do not force the piston into cylinder.

6) Position the boot in the grooves on cylinder and
piston.

7) Apply a coat of specified grease to inner surface
of cylinder, lock pin, guide pin, periphery of bushing
and boot grooves.

Grease:

NIGLUBE RX-2 (Part No. K0779GA102)

(1) Piston seal

BR-00240

(1)

BR-00027

(1) Piston

(2) Piston boot

(1) Piston

(2) Piston boot

(3) Caliper body

(4) Piston seal

BR-00242

(1)

(2)

BR-00243

(1)

(2)

(3)

(4)

BR-24

BRAKE

Front Disc Brake Assembly

8) Install the lock pin and guide pin boot on support.

2. 16-INCH TYPE

Refer to 15-inch type. <Ref. to BR-23, 15-INCH
TYPE, ASSEMBLY, Front Disc Brake Assembly.>

3. 17-INCH TYPE

Refer to 15-inch type. <Ref. to BR-23, 15-INCH
TYPE, ASSEMBLY, Front Disc Brake Assembly.>

E: INSPECTION

1) Repair or replace the faulty parts.
2) Check the caliper body and piston for uneven
wear, damage or rust.
3) Check the rubber parts for damage or deteriora-
tion.

(1) Pin boot

(2) Lock pin or guide pin

(3) Apply grease.

BR-00362

(1)

(2)

: (3)