Brake System (Front): Removal & Installation Subaru BRZ ZC

Removal

Note. The following procedure is for LH side. Service the LH side and the RH side using the same procedure.

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1. Removal of front tire
2. Draining of brake fluid CAUTION: Do not let brake fluid come into contact with the painted surface. If it happens, wash it out immediately.
3. Disconnection of front flexible hose No. 1 Remove a union bolt and 2 gaskets to disconnect the front flexible hose No. 1 from the front disk brake cylinder ASSY LH.
4. Removal of front disc brake cylinder ASSY LH Remove 2 bolts and then remove the front disc brake cylinder ASSY LH.
5. Removal of front disc brake pad (15 inch type) Remove the disc brake pad from the front disc brake cylinder mounting LH. Remove the cover (shim) and the shim from each pad.
6. Removal of front disc brake pad (16 inch type) Remove the disc brake pad from the front disc brake cylinder mounting LH.
7. Removal of spring (L) Remove the spring (L) from the front disc brake cylinder mounting LH.
8. Removal of spring (pad) Remove the spring (pad) from the front disc brake cylinder mounting LH.
9. Removal of front disc brake cylinder slide pin Remove the front disc brake cylinder slide pin from the front disc brake cylinder mounting LH.
10. Removal of front disc brake cylinder slide pin No. 2 Remove the front disc brake cylinder slide pin No. 2 from the front disc brake cylinder mounting LH.
11. Removal of boot (pin) Remove the boot (pin) from the front disc brake cylinder mounting LH.
12. Removal of bushing Using a thin flat tip screwdriver wrapped with a protective tape, remove the bushing from the pin (B).
13. Removal of front disc brake cylinder mounting LH Remove 2 bolts and then the front disc brake cylinder mounting LH.
14. Removal of front disc Put alignment marks on the front disc and front axle hub. (It's not necessary when replacing the disc). Remove the front disc.

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1. Removal of cylinder boot Remove 2 cylinder boots. CAUTION: To prevent the front disc brake piston from being scratched, always remove the boot with hands without using a tool like a screwdriver.
2. Removal of front disc brake piston Put a wooden block between the pistons of the cylinder ASSY to prevent the pistons from popping out. Using an air gun, gradually blow air into the applicable part to remove the 2 front disc brake pistons from the cylinder. WARNING: Be careful not to pinch your fingers. CAUTION: Be careful not to spill brake fluid. NOTE: Replace the front disc brake cylinder ASSY, if the front disc brake piston is damaged. Remove the wooden block.
3. Removal of piston seal Using a thin flat tip screwdriver, remove 2 piston seals from the cylinder ASSY. NOTE: Wrap the tip of the thin flat tip screwdriver with a protective tape. CAUTION: Do not damage inside the cylinder and the seal groove.
4. Removal of front disc brake bleeder plug cap Remove the front disc brake bleeder plug cap from the front disc brake bleeder plug.
5. Removal of front disc brake bleeder plug Remove the front disc brake bleeder plug.

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1. Disc brake piston and cylinder check Check that there is no damage on the side of the disc brake piston and the cylinder wall.
2. Disc brake pad thickness check Limit: 1.5mm {0.059in} Reference value:: 11.0mm {0.433in} (New)
3. Front disc thickness check Limit: 22.0mm {0.866in} Reference value:: 24.0mm {0.945in} (New)
4. Disc runout check Before checking the disc runout, check the hub & bearing ASSY's play and runout. (Refer to «ON-VEHICLE INSPECTION»(ref-619162-S21661549242014053000000) ) Install the front disc to the axle hub and secure it with 5 hub nuts. Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf} Using a dial gauge, check the runout 10 mm{0.394 in} inside of the disc outer periphery. Limit: 0.05mm {0.002in} CAUTION: Do not bring the magnetized part of the dial gauge close to the axle hub or speed sensor. Install the dial gauge to the shock absorber. When the runout exceeds the limit, change the disc and axle positions to minimize the runout and install them. If the runout still exceeds the limit even after changing the positions, replace the disc with a new one.

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1. Temporarily tightening of front disc brake bleeder plug Temporarily tighten the front disc brake bleeder plug to the front disc brake cylinder ASSY LH.
2. Installation of front disc brake bleeder plug cap Install the front disc brake bleeder plug cap to the front disc brake bleeder plug.
3. Installation of piston seal Apply rubber grease all around 2 new piston seals. Securely install 2 piston seals to the disc brake cylinder grooves.
4. Installation of front disc brake piston Apply rubber grease to a new cylinder boot. Securely install the cylinder boot to the front disc brake piston groove. Apply a thin coat of rubber grease to the outer peripheries of 2 front disc brake pistons, and install them to the front disc brake cylinder ASSY LH. CAUTION: Do not push the front disc brake piston in with excessive force.
5. Installation of cylinder boot Securely install the cylinder boot to the front disc brake cylinder ASSY LH groove.

Installation

Note. The following procedure is for LH side. Service the LH side and the RH side using the same procedure.

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1. Installation of front disc When removing/installing the front disc Aligning the mark which you put at the time of removal, install the front disc to the axle hub. When replacing the front disc Check the disc runout (Refer to «INSPECTION»(ref-619202-S28753684402014053000000) ) and install the front disc to the axle hub. Temporarily tighten the hub nut to secure the front disc to the axle hub.
2. Installation of front disc brake cylinder mounting LH Install the carriers with new 2 bolts. Standard value: T=80N.m {816kgf.cm} {59.0ft.lbf}
3. Installation of boots (pins) Apply rubber grease all around the engaging parts of new 2 boots (pins). NOTE: Apply 1.5±2.0g of rubber grease (NIGLUBE RX-2) per 1 front disc brake bushing dust boot. Install 2 front disc brake bushing dust boots to the front disc brake cylinder mounting LH.
4. Installation of bushing Apply a thin coat of rubber grease all around the contacting surface of the new bushing and the front disc brake cylinder slide pin No. 2. Install the bushing to the front disc brake cylinder slide pin No. 2.
5. Installation of front disc brake cylinder slide pin No. 2 Apply a thin coat of rubber grease all around the engaging part and the sliding part of the front disc brake cylinder slide pin No. 2. Install the front disc brake cylinder slide pin No. 2 to the carrier.
6. Installation of front disc brake cylinder slide pin Apply a thin coat of rubber grease all around the engaging part and the sliding part of the front disc brake cylinder slide pin. Install the front disc brake cylinder slide pin to the carrier.
7. Installation of spring (L) Apply a thin coat of MP grease to the part where the disc brake pad kit FR for the spring (L) contacts. Install the spring (L) to the front disc brake cylinder mounting LH.
8. Installation of spring (pad) NOTE: Service the spring (pad) in the same procedures for the spring (L).
9. Removal of front disc brake pad (15 inch type) Apply disc brake grease II to both sides of the shim. Install the front disc brake pad to the cover (shim). Install the disc brake pad, the cover (shim) and the shim to the carrier.
10. Installation of front disc brake pad (16 inch type) Install the disc brake pad to the carrier.
11. Installation of front disc brake cylinder ASSY LH Install the front disc brake cylinder ASSY LH to the carrier with 2 bolts. Standard value: T=26N.m {270kgf.cm} {19.2ft.lbf}
12. Connection of front flexible hose No. 1 Using a new union bolt, connect the front flexible hose No. 1 to the disc brake cylinder ASSY via 2 new gaskets. Standard value: T=18N.m {184kgf.cm} {13.3ft.lbf}
13. Brake fluid refill (Refer to «BRAKE FLUID»(ref-619168-S38448254732014053000000) )
14. Air bleeding of brake system (Refer to «AIR BLEEDING»(ref-619168-S03727984982014053000000) )
15. Brake fluid leak check
16. Brake fluid level check (Refer to «ON-VEHICLE INSPECTION»(ref-619168-S01732739622014053000000) )
17. Installation of front tire Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf}

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Note. The following procedure is for LH side. Service the LH side and the RH side using the same procedure.

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1. Removal of front tire
2. Draining of brake fluid CAUTION: Do not let brake fluid come into contact with the painted surface. If it happens, wash it out immediately.
3. Removal of front flexible hose No. 1 Remove the bolt and disconnect the front flexible hose No. 1 from the front shock absorber ASSY. Remove the union bolt and 2 gaskets, and then remove the front flexible hose No. 1. Secure the flexible hose No. 1 with a spanner, and disconnect the brake tube using a flare-nut wrench. CAUTION: Do not bend or damage the brake tubes. Do not let foreign matter including dirt and dust enter the connection part of the brake tube. Remove the clip. Remove the front flexible hose No. 1.

Note. The following procedure is for LH side. Service the LH side and the RH side using the same procedure.

1. Installation of front flexible hose No. 1 With a new clip, install the front flexible hose No. 1. CAUTION: Securely attach the clip as far as it will go. Secure the flexible hose No. 1 with a spanner, and connect the brake tube to the front flexible hose No. 1 using a flare-nut wrench. Standard value: T=15N.m {155kgf.cm} {11.1ft.lbf} CAUTION: Do not bend or damage the brake tubes. Do not let foreign matter including dirt and dust enter the connection part of the brake tube. With a bolt, install the front flexible hose No. 1 to the front shock absorber ASSY. Standard value: T=33N.m {337kgf.cm} {24.3ft.lbf} Using a new union bolt, install the front flexible hose No. 1 to the disc brake cylinder ASSY via 2 new gaskets. Standard value: T=18N.m {184kgf.cm} {13.3ft.lbf}
2. Brake fluid refill (Refer to «BRAKE FLUID»(ref-619168-S38448254732014053000000) )
3. Air bleeding of brake system (Refer to «AIR BLEEDING»(ref-619168-S03727984982014053000000) )
4. Brake fluid leak check
5. Brake fluid level check (Refer to «ON-VEHICLE INSPECTION»(ref-619168-S01732739622014053000000) )
6. Installation of front tire Standard value: T=120N.m {1224kgf.cm} {88.5ft.lbf}