I just got an 84 wagon (well will just soon be getting it) and it seems to need some brake help. I once tried to do the brakes in an 81 model, as if it was an american car and it was a disaster! The whole caliper was covered in rubber and it immediately cracked and leaked fluid and our only choice was to go to a shop and pay $300 for them to rebuild each caliper which they claimed was necessary on these cars every time you need to do the brakes. Is it really necessary to rebuild the caliper every time, and if so can I do it at home with somewhat limited tools? (What specifically do I need.) Or is there a way to do the brakes without damaging the delicate rubber housing.

well on a 84 the rubber has already had a reasonable life being 21 years old.

Gee that answers my dilemma......NOT!

 

Sorry but that is truly unhelpful.....

 

I need to know if I can either save the caliper since it is functioning without leaks, or if I can rebuild the caliper at home, simple as that?!?

 

BTW I know 30 year old American cars with still funtional rubber on their calipers so age is not always the issue. Design is.

Is it really necessary to rebuild the caliper every time, and if so can I do it at home with somewhat limited tools? (What specifically do I need.) Or is there a way to do the brakes without damaging the delicate rubber housing.

ABOLUTELY

the front brake pistons must be "turned" in to the calipers NOT PRESSED IN WITH A C CLAMP!! - any aftermarket manual covers the proceedure - basically you swing the caliper up, remove the old pads, then use something to "turn" the piston in - I'm pretty sure there are lots of posts about it - I did my front brakes less than six months ago - car is an '85 - all brake components are orig. and never rebuilt

 

there is info on the proceedure here: http://www.ultimatesubaru.org/forum/article.php?a=29

if the caliper isn't currently leaking or sticking you should be able to slap new pads on there and go about your business without touching the calipers. i've had a couple soobs with 200,000+ miles (my current daily driver has 220,000) on the original calipers. i've rebuilt and am about to rebuild the ones on my daily driver. rebuild kit costs like less than 10 dollars and has the seals to rebuild both calipers. doesn't require any special tools and is easy enough to do, just did a set last week for one of my XT6's. turning the piston back in is the most annoying part, just be patient and keep turning. the new seal will make it a tight fit, but just keep turning it and keep at it. not much to it really, either use the e-brake lever (if off the car) or the brake pedal (caliper still on car) and keep working them until the piston comes all the way out. or you can blow compressed air through the brake line port. push the piston all the way out. remove the rubber dust seal and clip that holds it in place. clean out the caliper bore and the piston, install the new seal and rubber boot and you're done. there's only 3 parts to each caliper - piston seal and rubber boot (with clip to hold in place), that's it. very simple set up really and not hard to do at all, just takes time like anything else. the outer rubber you see is just a dust shield really, shouldn't be holding back fluid. if there is fluid behind the dust boot then the piston or seal has been compromised in some way.

a caliper rebuild every time? that sounds like BS to me, but what do i know, i'm not an EA81 owner. i've owned all XT models, so i don't know EA81's, but i've never heard of rebuilding a caliper every time. throw on some new brake pads and you're good to go. like mentioned earlier, if the piston needs to be turned in, then be sure to have the right tool and screw the piston back instead of using a C Clamp. the piston on XT6's on the front calipers for example ride on a threaded spindle and have to be turned in ordered to retract or they won't go in. a c-clamp won't work. you've already had these rebuilt, so just slap some new pads on there and be on your way.