Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Brake Caliper

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REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

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Fig. Fig. 1: Loosen the brake hose retainer bolt ...



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Fig. Fig. 2: ... and remove the retainer bolt. Discard the sealing washers



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Fig. Fig. 3: Loosen and remove the caliper bracket upper and lower retainer bolts



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Fig. Fig. 4: Lift the caliper and bracket assembly off the rotor and spindle assembly


WARNING
Before beginning the procedure, determine whether your vehicle is equipped with a front parking brake assembly. If equipped with front parking brakes, only compress the piston slightly, or the piston screw could be damaged.

  1. Remove as much brake fluid as possible from the master cylinder reservoir.
  2.  
  3. Raise and support the vehicle safely on jackstands. Remove the front wheels.
  4.  
  5. Use a C-clamp to compress the piston into the caliper bore.
  6.  

If your vehicle is equipped with front parking brakes, compress the piston only slightly.

  1. Release the parking brake and disconnect the cable from the caliper lever, if equipped.
  2.  
  3. Remove the brake hose from the caliper body and plug the hose to prevent the entrance of dirt or moisture.
  4.  
  5. Remove the caliper bracket retainer bolts.
  6.  
  7. Slide the caliper and bracket assembly off the spindle and rotor.
  8.  
  9. Remove the brake pads, backing plates and retainer clips.
  10.  
  11. Compress the piston assembly into the cylinder bore.
  12.  

If equipped with parking brake, use a suitable tool to rotate the piston back into the caliper bore.

To install:
  1. Install the caliper bracket to the spindle assembly, and secure in place with the retainer bolts. Tighten the retainer bolts to 25-33 ft.lbs. (32-43 Nm).
  2.  
  3. Install the pad retainer clips, brake pads, backing plates and caliper.
  4.  
  5. Install the hand brake cable, if equipped.
  6.  
  7. Connect the brake hose using new sealing washers, and tighten the fitting to 11-15 ft. lbs. (15-21 Nm).
  8.  
  9. Bleed the brake system. Install the wheels and lower the vehicle. Check the fluid level in the master cylinder.
  10.  

OVERHAUL



See Figures 5, 6, 7, 8, and 9

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Fig. Fig. 5: Place the caliper assembly on a clean work surface and remove the bracket



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Fig. Fig. 6: Position a piece of wood as shown, then use low pressure compressed air to push out the piston



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Fig. Fig. 7: Remove the piston from the caliper assembly and inspect



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Fig. Fig. 8: Remove the piston boot from the caliper ...



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Fig. Fig. 9: ... and the seal from inside the caliper bore

  1. Remove the brake caliper from the vehicle and place on a clean work surface.
  2.  
  3. Remove the inlet fitting from the brake caliper and drain all brake fluid.
  4.  
  5. Place a piece of wood in the caliper opening. Use low pressure compressed air and force the piston from the bore.
  6.  


CAUTION
DO NOT apply high pressure compressed air to the caliper bore. The piston may jump out, causing damage to the piston and/or the operator. Be ABSOLUTELY SURE to keep your fingers away from the piston while air is being applied.

  1. Remove and discard the piston boot and seal. Be careful not to scratch the bore while removing the pieces. Use of a metal tool is NOT recommended.
  2.  
  3. Inspect the piston and the caliper bore for damage or corrosion. Replace the caliper and/or the piston if necessary.
  4.  
  5. Remove the bleeder screw and rubber cap if equipped.
  6.  
  7. Clean all of the parts with non-mineral based solvent and blow dry with compressed air. All rubber parts should be replaced.
  8.  
  9. Inspect the guide pins for corrosion, replace if necessary. When installing the guide pins, coat them with a silicone lubricant.
  10.  

To assemble:
  1. Lubricate the piston, caliper and seal with clean brake fluid.
  2.  
  3. Install the seal into the caliper bore making sure it is not twisted in the bore groove.
  4.  
  5. Install the boot onto the piston, then position the piston into the caliper bore.
  6.  
  7. If the caliper is equipped with the parking brake, then use a suitable tool to rotate the piston back into the caliper bore.
  8.  
  9. If not equipped with a parking brake, bottom the piston into the bore using your hand and a piece of wood to compress the piston.
  10.  
  11. Install the bleeder valve and tighten to 6-7 ft. lbs. (8-9 Nm).
  12.  
  13. Install the caliper to the vehicle and properly bleed the hydraulic brake system.
  14.  

 
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