Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Brake Disc (Rotor)

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REMOVAL & INSTALLATION



1985-86 Models
  1. Raise the vehicle and support safely on jackstands.
  2.  
  3. Remove the front wheel, handbrake cable, caliper and caliper bracket. Support the caliper to a suspension part using a piece of wire. Make sure the brake hose is not distorted.
  4.  
  5. Remove the axle shaft nut and pull the disc off the axle shaft with a puller.
  6.  
  7. Remove the 4 bolts which hold the disc to the hub.
  8.  
  9. Separate the hub from the rotor.
  10.  

To install:
  1. Position the hub to the rotor, making sure the retainer bolts holes align.
  2.  
  3. Install the hub-to-rotor retainer bolts, and tighten to 36-51 ft. lbs. (48-69 Nm).
  4.  
  5. Install the hub/rotor assembly on the halfshaft. Tighten the nut to specification.
  6.  
  7. Install the caliper bracket, followed by the caliper and brake pads.
  8.  
  9. Install the wheel and tire assembly, and lower the vehicle.
  10.  

1987-96 Models

See Figures 1 and 2

Click image to see an enlarged view

Fig. Fig. 1: To separate the rotor from the hub assembly, install and tighten two bolts into the rotor's holes-Legacy shown



Click image to see an enlarged view

Fig. Fig. 2: When the rotor is freed from the hub, slide it off the studs

  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Remove the rear wheel and tire assembly
  4.  
  5. Remove the brake caliper and bracket assembly, and suspend out of the way with a piece of wire.
  6.  
  7. Remove the conical spring(s) around one or more of the lug studs.
  8.  
  9. Thread two suitably sized metric bolts into the holes in the rotor hat. Evenly tighten both bolts to separate the rotor from the hub assembly.
  10.  
  11. Pull the rotor from the hub and halfshaft.
  12.  

To install:
  1. Install the hub and disc assembly on the axle shaft. Install the conical spring and castle nut and temporarily tighten. Ensure that the conical spring is installed in the correct direction.
  2.  
  3. Install the caliper assembly and tighten the bolts to specification.
  4.  
  5. Install the castle nut and tighten to specification. Install the wheels and lower the vehicle.
  6.  

INSPECTION



See Figure 3

Click image to see an enlarged view

Fig. Fig. 3: Checking disc run-out

Check the disc brake rotor for scoring, cracks or other damage. If rotor run-out is checked, this should be measured while the rotor is installed. Use a dial gauge to check rotor run-out.

  1. Raise and support the rear of the vehicle safely using jackstands.
  2.  
  3. Remove the rear wheels.
  4.  
  5. Visually inspect the rotor for cracks, excessive scoring or other damage. A light scoring of the surface is normal and should not be considered detrimental to brake operation.
  6.  

Before attempting to check rotor run-out on all vehicles, the bearings must be in good condition and exhibit no excessive play.

  1. Check the disc for excessive run-out using a dial indicator:
    1. Position and secure a dial indicator so that the button contacts the disc about 0.20 in. (5mm) from the outer edge. Set the dial indicator to zero.
    2.  
    3. Rotate the disc one complete revolution. The lateral run-out reading should not exceed 0.039 in. (0.10mm). If the reading is excessive, recondition or replace the disc.
    4.  

  2.  
  3. Check the disc minimum thickness and the disc parallelism (thickness variation):
    1. Use a micrometer to check the disc thickness at 4 locations around the disc. Make sure the measuring point is at the same distance from the edge at all locations.
    2.  
    3. The thickness should be greater than the minimum specification (which is normally cast onto the disc) and should not vary more than 0.0005 in. (0.013mm). If the variations are excessive, recondition or replace the disc. A disc which is smaller than the discard dimension MUST be replaced for safety.
    4.  

  4.  

Refinishing of brake rotors can be handled at machine shops equipped for brake work.

 
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