Subaru Legacy III (2000-2003 year). Manual - part 816

BR-22

BRAKE

FRONT DISC ROTOR

3. Front Disc Rotor

A: REMOVAL

1) Loosen wheel nuts, jack-up vehicle, support it
with safety stands, and remove wheel.
2) Remove caliper body from housing, and sus-
pend it from strut using a wire.

3) Remove the disc rotor.

NOTE:
If disc rotor seizes up within the hub, drive disc rotor
out by installing an 8-mm bolt in holes B on the ro-
tor.

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

B: INSTALLATION

1) Install the disc rotor.
2) Install the caliper body to housing.

Tightening torque:

78 N·m (8 kgf-m, 58 ft-lb)

C: INSPECTION

1) Secure disc rotor by tightening the five wheel
nuts.
2) Set a dial gauge on the disc rotor. Turn disc rotor
to check runout.

NOTE:
• Make sure that dial gauge is set 5 mm (0.20 in)
inward of rotor outer perimeter.
• If disc rotor runout is above standard value, in-
spect play of hub bearing axial direction and runout
of axle hub.
<Ref. to DS-22, INSPECTION, Front Axle.>
If bearing and hub are normal, replace disc rotor.

Disc rotor runout limit:

0.075 mm (0.0030 in)

3) Measure disc rotor thickness.
If thickness of disc rotor is outside the standard val-
ue, replace disc rotor.

NOTE:
Make sure that micrometer is set 5 mm (0.20 in) in-
ward of rotor outer perimeter.

BR-00017

BR-00018

A

B

Standard 

value

Service 

limit

Disc outer 

dia.

Disc rotor 
thickness A

15

″

24.0 mm

(0.945 in)

22.0 mm

(0.866 in)

277 mm

(10.91 in)

16

″

24.0 mm

(0.945 in)

22.0 mm

(0.866 in)

294 mm

(11.57 in)

BR-00019

BR-00018

A

B

BR-23

BRAKE

FRONT DISC BRAKE ASSEMBLY

4. Front Disc Brake Assembly

A: REMOVAL

1) Loosen wheel nuts, jack-up vehicle, support it
with safety stands, and remove wheel.
2) Remove union bolt and disconnect brake hose
from caliper body assembly.

CAUTION:
Do not spill brake fluid on painted surface. 
Wash it off immediately.

3) Remove bolt securing lock pin to caliper body.

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

NOTE:
Remove support only when replacing it or the rotor.
It need not be removed when servicing caliper body
assembly.

6) 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.

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

B: INSTALLATION

1) Install disc rotor on hub.
2) Install support on housing.

Tightening torque:

78 N·m (8 kgf-m, 58 ft-lb)

CAUTION:
• Replace pad clips if they are twisted or worn.
• A wear indicator is provided on the inner disc
brake pad. If the pad wears down to such an ex-
tent 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, re-
place the pad.
• When replacing the pads, replace pads of the
right and left wheels at the same time.
3) Install pads on support. <Ref. to BR-20, IN-
STALLATION, Front Brake Pad.>
4) Install caliper body on support.

Tightening torque:

39 N·m (4.0 kgf-m, 28.9 ft-lb)

5) Connect brake hose.

Tightening torque:

18 N·m (1.8 kgf-m, 13.0 ft-lb)

CAUTION:
Replace brake hose gaskets with new ones.
6) Bleed air from brake system. <Ref. to BR-42,
PROCEDURE, Air Bleeding.>

BR-00021

BR-00022

BR-00023

BR-00018

A

B

BR-24

BRAKE

FRONT DISC BRAKE ASSEMBLY

C: DISASSEMBLY

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

CAUTION:
Be careful not to allow foreign particles to enter 
inlet (at brake hose connector).
2) Using a standard screwdriver, remove boot ring
from piston.

3) Remove the boot from piston end.
4) Place a wooden block as shown in the figure to
prevent damage to the piston. Gradually supply
compressed air via inlet of the brake hose to force
piston out.

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

CAUTION:
Be careful not to scratch the inner surface of 
cylinder and piston seal groove.

6) Remove the lock pin boot and 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) Insert the piston into cylinder.

CAUTION:
Do not force the piston into cylinder.

(1) Boot ring

(1) Place a 30 mm (1.18 in) wide wooden block 

here.

BR-00217

( 1 )

BR-00026

( 1 )

(1) Piston seal

BR-00027

( 1 )

BR-00028

BR-25

BRAKE

FRONT DISC BRAKE ASSEMBLY

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.

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 the lock pin
and guide pin, outer surface, cylinder inner surface,
and boot grooves.

Grease:

NIGLUBE RX-2 (Part No. K0779GA102)

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

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 boot 

(2) Boot ring

(3) Piston seal

(4) Caliper body

(1) Pin boot

(2) Lock pin or guide pin

(3) Apply grease.

BR-00029

( 1 )

( 2 )

( 3 )

( 4 )

BR-00030

:

( 1 )

( 2 )

( 3 )