Disc & Drum: Removal & Installation Subaru Forester SF

Removal

Raise and support vehicle. Remove wheel. Remove lower caliper guide pin bolt. Rotate caliper body up and away from disc. Remove pads, clips and shims from caliper support bracket. Standard front pad thickness is .67" (17.0 mm). Minimum front pad thickness, including metal backing plate, is .295" (7.49 mm). On SVX, minimum pad thickness (pad only) is .059" (1.5 mm).

Installation

Push piston(s) into caliper body. Install anti-squeak shims on both inner and outer pads. Install pad clips to support bracket and install pads. Rotate caliper body down, aligning piston notches with pad tabs. Install lower caliper guide pin bolt. Reconnect parking brake cable. Depress brake pedal several times to set pad-to-rotor clearance.

Raise and support vehicle. Remove wheel. Disconnect brakeline from caliper and plug openings. Remove brake caliper guide pin bolts from brake caliper support bracket. Remove caliper. DO NOT remove pads or support bracket unless rotor is being removed.

Apply silicone grease to guide pin, boot and guide pin bolt. Install caliper assembly, pads and parking brake cable. Install brakeline. Bleed hydraulic system. See BLEEDING BRAKE SYSTEM .

Raise and support vehicle. Remove wheel. Remove caliper assembly and wire it aside. DO NOT disconnect brakeline from caliper. Remove caliper support bracket with attached disc pads from steering knuckle. Remove rotor from hub assembly. If rotor seizes to hub, use 8-mm bolts in screw holes on rotor to remove rotor.

To install, reverse removal procedure. Tighten hub-to-rotor bolts evenly to specification. See TORQUE SPECIFICATIONS . Depress brake pedal several times to seat pads.

Siphon brake fluid from master cylinder. Disconnect PHV cable at PHV. see scheme 2and see scheme 4. Disconnect brakelines from PHV. Remove PHV from support bracket. Plug all lines and fittings.

Note. DO NOT disassemble PHV. If PHV is defective, replace assembly.

To install, reverse removal procedure. Apply grease to hook of return spring, cable end portion of lever and cable end portion of clutch release fork. Bleed hydraulic system and adjust PHV cable. See BLEEDING BRAKE SYSTEM . See HILL-HOLDER BRAKE under ADJUSTMENTS .

Removal & Installation

Drain brake fluid from reservoir. Disconnect warning light fluid level connection. Remove brake pipes lines. Remove master cylinder from brake booster. To install, reverse removal procedure. Bleed hydraulic system. See BLEEDING BRAKE SYSTEM .

1. Raise and support vehicle. Remove wheel. Remove lower guide pin bolt. Rotate caliper upward and wire it aside. Remove brake pads from support bracket, noting positions of shims and clips.
2. Standard rear pad thickness is .591" (15.00 mm). Minimum pad thickness, including metal backing plate, is .256" (6.50 mm). To install, reverse removal procedure. Open caliper bleeder screw and press piston back into caliper bore. Bleed brake system (if necessary). See «BLEEDING BRAKE SYSTEM»(ref-121756-S30450498552001090500000) .

1. Raise and support vehicle. Remove wheel. Remove rear caliper from support bracket and wire it aside. Remove pads and support bracket from rear axle housing. Pull rotor from hub (outboard type rotor). Remove rotor from hub assembly. If rotor seizes to hub, use 8-mm bolts in screw holes on rotor to remove rotor.
2. To remove disc rotor from hub, loosen parking brake shoe adjustment by inserting a screwdriver through backing plate access hole to turn adjusting star wheel. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-121756-S33067261722001090500000) .

1. Raise and support vehicle. Remove rear wheels. Release parking brake. Remove brake drum. If drum is difficult to remove, remove adjusting hole cover from backplate. Insert a screwdriver through backplate access hole and back off adjuster.
2. Remove springs and brake shoes. (Scheme 1) To install, reverse removal procedure. Apply a small amount of brake grease to all brake shoe-to-backplate contract areas.

Scheme 1

1. Remove disc brake assembly from support and wire it aside. To remove disc rotor from hub, loosen parking brake shoe adjustment by inserting a screwdriver through backing plate access hole to turn adjusting star wheel. Remove disc rotor from hub. (Scheme 2)
2. Remove shoe return springs. Remove front shoe hold-down spring and pin. Remove strut and strut spring. Remove adjuster star wheel assembly. Remove brake shoe. Remove rear shoe hold-down spring and pin. Remove parking brake cable from lever. Remove lever and washer from shoe. To install, reverse removal procedure. Adjust parking brake. See «PARKING BRAKE»(ref-121756-S02657376162001090500000) under ADJUSTMENTS.

Scheme 2

1. From inside vehicle, remove brake bracket, snap pin and clevis pin. Remove brake booster retaining nuts from firewall inside vehicle. Remove master cylinder. See «MASTER CYLINDER»(ref-121756-S40890102942001090500000) .
2. Disconnect vacuum hose at brake booster. Remove brake booster.

1. Check booster-to-master cylinder push rod length at measurement "L". (Scheme 3) Length should be.394" (10.00 mm). Use care when handling booster assembly. Excessive lateral force to operating rod will damage power piston cylinder.
2. Ensure booster resin material around brake pedal rod is not damaged. Replace booster assembly if it is dropped. To install, reverse removal procedure. Bleed air from system. See «BLEEDING BRAKE SYSTEM»(ref-121756-S30450498552001090500000).

Scheme 3