Subaru Legacy (2005 year). Manual - part 825

BR-29

BRAKE

Rear Disc Brake Assembly

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 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 the 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, guide pin, lock pin, periphery of bushing
and boot grooves.

Grease:

NIGLUBE RX-2 (Part No. K0779GA102)

8) Install the guide pin boot on support.
9) Install the lock pin boot on support, and then in-
sert the lock pin sleeve into specified point.

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) Piston

(2) Piston boot

(3) Caliper body

(4) Piston seal

BR-00043

BR-00243

(1)

(2)

(3)

(4)

(1) Pin boot

(2) Lock pin or guide pin

(3) Apply grease.

BR-00362

(1)

(2)

: (3)

BR-30

BRAKE

Master Cylinder

8. Master Cylinder

A: REMOVAL

CAUTION:
Do not allow brake fluid to come in contact with 
vehicle body; wash away with water and wipe 
off completely if spilled.
1) Thoroughly drain the brake fluid from reservoir
tank.
2) Disconnect the fluid level gauge harness con-
nector.
3) Remove the brake pipes from master cylinder.
4) Remove the master cylinder mounting nuts, and
take out the master cylinder from brake booster.

B: INSTALLATION

1) Replace the O-ring for the master cylinder with a
new one.

CAUTION:
Do not install the O-ring in wrong place.

2) Install in the reverse order of removal.

Tightening torque:

Master cylinder mounting nut

13 N

⋅

m (1.3 kgf-m, 9.6 ft-lb)

Piping flare nut
Model with ABS

15 N

⋅

m (1.5 kgf-m, 10.8 ft-lb)

Model with VDC

19 N

⋅

m (1.9 kgf-m, 14.0 ft-lb)

CAUTION:
Be sure to use recommended brake fluid.
3) Bleed air from brake system. <Ref. to BR-38,
PROCEDURE, Air Bleeding.>

C: REPLACEMENT

CAUTION:
When the master cylinder assembly is re-
placed, be sure to put the label on reservoir 

tank at the specified position as shown in the 
figure.

Label

Parts No. 26191TA000

• LHD model

• RHD model

1) Remove mud and dirt from the surface of brake
master cylinder.
2) Secure the master cylinder on a vise.

NOTE:
To avoid damaging master cylinder, use aluminum
plate while holding with vise.
3) Remove the pin which secures the reservoir tank
to master cylinder, and then remove the reservoir
tank and seal.

(1) Primary piston

(2) O-ring

(3) Do not install the O-ring on this groove.

(1)

(2)

(3)

BR-00363

(1) Label

(1) Label

BR-00476

(1)

BR-00474

(1)

BR-00364

BR-31

BRAKE

Master Cylinder

4) With pushing-in the primary piston, remove the
C-ring using pliers.

5) With pushing-in the primary piston, remove the
straight pin from the port on installation part of res-
ervoir tank using magnet pick-up tool.

6) Extract the primary piston assembly and sec-
ondary piston assembly straight out, while taking
care not to scratch the inner surface of cylinder.
7) Clean the inside of master cylinder with brake
fluid. Check the inside of cylinder for damage, de-
form, wear and rust. Replace the master cylinder
as assembly if faulty.
8) Apply brake fluid to the inner surface of master
cylinder and piston assembly.
9) Ensure that the inner surface of master cylinder
and piston assembly are free of dirt before assem-
bling. Install the primary piston assembly and sec-
ondary piston assembly to master cylinder, while
taking care not to scratch the master cylinder inner
surface.
10) With pushing-in the primary piston, install the
cylinder pin.

11) With pushing-in the primary piston, install the
C-ring to groove using pliers.

CAUTION:
Ensure the secure installation to the groove.
12) Install the seal to reservoir tank.

13) Install the reservoir tank to master cylinder, and
secure with pin.
14) Replace the O-ring for the master cylinder with
a new one.

(1) Straight pin

BR-00169

(1)

BR-00069

(1) Seal

(1) Primary piston

(2) O-ring

(3) Do not install the O-ring on this groove.

BR-00169

(1) 

BR-00072

(1)

(2)

(3)

BR-00363

BR-32

BRAKE

Master Cylinder

D: INSPECTION

Inspect for oil leakage from the master cylinder.

NOTE:
After replacing piston kit; when the oil leakage is
found without damaging or scratching the inside of
cylinder, wear of master cylinder inner wall may be
the cause. In this case, replace the master cylinder
as assembly.