Subaru ff-1/1300/1400/1600/1800/Brat 1970-1984 Repair Guide

Brake Pads

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INSPECTION





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Fig. Fig. 1 Measure the pad thickness, if it is not within specifications they must be replaced

Inspect the brake pads for excessive or uneven wear, fluid contamination, bent and/or broken parts and cracks. If any of these conditions exist, replace the brake shoes.

Check the brake pads for wear and replace them if the thickness is less than 0.058 in. (1.5mm) on 1975-79 models. On later models, the usable thickness including the backing should be no less than 0.29 in. (7.5mm). Replace all 4 brake pads together to prevent the braking from being uneven.

REMOVAL & INSTALLATION



1975-79 Models
  1. Raise the front of the car and support it with jackstands. Remove the wheel and tire.
  2.  


CAUTION
Be sure that the car is securely supported.

  1. Remove the parking brake cable by disengaging the outer cable clip.
  2.  



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Fig. Fig. 2 Exploded view of the disc brake assembly-1975-79 models

  1. Remove the 4 pins from the caliper guides.
  2.  
  3. Fit the tip of a screwdriver on the guide and tap lightly to drive the guide out. When one is removed, the other one can be easily removed.
  4.  


WARNING
It is not necessary to remove the brake line.

  1. Remove the caliper by firmly holding the caliper body and pulling the lower part out while pushing the upper part in. Safety wire the caliper out of the way.
  2.  
  3. Remove the disc brake pad.
  4.  

To install:


CAUTION
Do not try to force the piston back into the caliper body without turning as damage to the threaded spindle may occur.

  1. Remove a small portion of brake fluid from the master cylinder reservoir. With an appropriate tool, turn the caliper piston clockwise into the cylinder bore and align the notches. Be sure the boot is not twisted or pinched.
  2.  
  3. Install the disc brake pads into the caliper.
  4.  
  5. Fit the caliper into the caliper housing and install the guides and pins.
  6.  
  7. Install the parking brake cable and outer cable clip.
  8.  
  9. Install the wheel and tighten the lug nuts.
  10.  
  11. Lower the vehicle and make sure that the brake pedal is firm.
  12.  

1980-84 Models
  1. Block the rear wheels. Raise the vehicle and the vehicle with jackstands.
  2.  
  3. Remove the wheel and tire.
  4.  
  5. Release the handbrake and disconnect the cable from the caliper lever.
  6.  
  7. On 1980-82 models, remove the 6mm lock pin bolt, (lower front of the caliper). Unfasten and disengage the lock pin. Make sure the lock pin is fully loosened before you try to remove it.
  8.  



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Fig. Fig. 3 Release the handbrake and disconnect the cable from the caliper lever



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Fig. Fig. 4 Unscrew and remove the lock pin, which is simply a long bolt



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Fig. Fig. 5 Swing the caliper up and away from the support and inspect the pads

  1. On 1983-84 models, simply unscrew and remove the lock pin, which is simply a long bolt.
  2.  
  3. The caliper will now pivot on its support. Swing the caliper up and away from the support and remove the pads.
  4.  



Click image to see an enlarged view

Fig. Fig. 6 Make sure to install pad retaining clips as shown

To install:

  1. Remove a small portion of brake fluid from the master cylinder reservoir. With an appropriate tool, turn the caliper piston clockwise into the cylinder bore and align the notches. Be sure the boot is not twisted or pinched.
  2.  


WARNING
Do not force the piston into the caliper body. The piston must be rotated clockwise at a rapid rate as it is forced in gently. Make sure the piston seal is not twisted. If it is, straighten it using a smooth, rounded screwdriver blade. Also, make sure the dowel on the back of the pad fits into the piston notch.

  1. Install the disc brake pads into the caliper.
  2.  
  3. Install the caliper.
  4.  
  5. Connect the handbrake cable to the caliper lever.
  6.  
  7. Install the wheel and tighten the lug nuts.
  8.  
  9. Lower the vehicle.
  10.  
  11. Pump the brake pedal until piston-to-pad clearance is taken up (keep reservoir full).
  12.  
  13. Make sure the brake pedal is firm before operating the car.
  14.  

 
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