Subaru Legacy III (2000-2003 year). Manual - part 818

BR-30

BRAKE

REAR DISC BRAKE ASSEMBLY

C: DISASSEMBLY

1) Remove the boot ring.

2) Remove the piston boot.

3) Gradually supply compressed air via inlet of cal-
iper body to force piston out.

CAUTION:
• Place a wooden block as shown in Figure to
prevent damage to piston.
• Do not apply excessively high-pressure.

4) Remove piston seal from caliper body cylinder.

5) Remove lock pin sleeve and boot from caliper
body.
6) Remove guide pin boot.

D: 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 sur-
face 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)

6) Install the piston boot to the caliper body, and at-
tach boot ring.

(1) Boot ring

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

block here.

BR-00040

( 1 )

BR-00041

BR-00042

( 1 )

(1) Piston boot

(2) Boot ring

(3) Piston seal

(4) Caliper body

BR-00043

BR-00029

( 1 )

( 2 )

( 3 )

( 4 )

BR-31

BRAKE

REAR DISC BRAKE ASSEMBLY

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)

8) Install guide pin boot on caliper body.
9) Install lock pin boot on caliper body and insert
lock pin sleeve into place.

E: 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.

(1) Pin boot

(2) Lock pin or guide pin

(3) Apply grease.

BR-00030

:

( 1 )

( 2 )

( 3 )

BR-32

BRAKE

MASTER CYLINDER

8. 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; wash it off quickly if spilt.

B: INSTALLATION

1) To install the master cylinder to the body, re-
verse the sequence of removal procedure.

Tightening torque:

Master cylinder mounting nut

14 N·m (1.4 kgf-m, 10.1 ft-lb)

Piping flare nut

15 N·m (1.5 kgf-m, 10.8 ft-lb)

2) Bleed air from the brake system. <Ref. to BR-42,
PROCEDURE, Air Bleeding.>

CAUTION:
Be sure to use recommended brake fluid.

C: DISASSEMBLY

CAUTION:
• Remove mud and dirt from the surface of
brake master cylinder.
• Prepare tools necessary for disassembly op-
eration, and arrange them neatly on work
bench.
• Clean work bench.
1) Remove pin with drift pin which secures reserve
tank to master cylinder.
2) Remove cylinder pin with magnetic pick-up tool
while pushing in primary piston.

3) Pry up the pawl and remove the piston retainer.
(Without VDC)

NOTE:
Piston may jump out from master cylinder.

4) Using pliers, remove C-ring. (With VDC)

NOTE:
Piston may jump out from master cylinder.

5) Extract primary piston assembly and secondary
piston assembly.

CAUTION:
• Do not disassemble the piston assembly;
otherwise, the spring set value may be
changed.
• Use brake fluid to wash inside wall of cylin-
der, pistons and piston cups. Be careful not to
damage parts when washing. 

D: ASSEMBLY

CAUTION:
• When assembling, be sure to use recom-
mended brake fluid.
• Ensure that the inside wall of cylinder, pis-
tons, and piston cups are free from dirt when
assembling.
• Be extremely careful not to damage, scratch,
or dent cylinder inside wall, pistons, and piston
cups.
• Do not drop parts. Never attempt to use any
part that has been dropped accidentally.
1) Apply recommended brake fluid to inside wall of
cylinder, and to outer surface of piston assembly,
and install piston assemblies carefully into cylinder.

(1) Cylinder pin

( 1 )

BR-00069

BR-00070

BR-00169

BR-33

BRAKE

MASTER CYLINDER

2) Install cylinder pin while pushing in primary pis-
ton.

3) Press the pawl and install the piston retainer into
the master cylinder. (Without VDC)

4) Using pliers, install C-ring in its groove. (With
VDC)

CAUTION:
Make sure to install it firmly to groove.

5) Install seal to reservoir tank.

6) Install pin with drift pins which secures reservoir
tank to master cylinder.

E: INSPECTION

If any damage, deformation, wear, swelling, rust,
and other faults are found on the primary piston as-
sembly, secondary piston assembly, supply valve
stopper, or gasket, replace the faulty part.

CAUTION:
• The primary and secondary pistons must be
replaced as complete assemblies.
• The service limit of the clearance between
each piston and the master cylinder inner dia.
is 0.11 mm (0.0043 in).
• When handling parts, be extremely careful
not to damage or scratch the parts, or let any
foreign matter get on them.

(1) Cylinder pin

( 1 )

BR-00069

BR-00070

BR-00169

(1) Seal

BR-00072

( 1 )