Disc & Drum: Removal & Installation Subaru Forester SF рестайлинг

Removal

1. Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel.
2. Remove lock pin.
3. Raise caliper body.
4. Remove pad. If brake pad is difficult to remove, proceed as follows: Remove caliper body and fasten it provisionally to coil spring. Remove support. Place support in a vise between wooden blocks. (Scheme 6) Attach a rod of less than 0.47" (12 mm) diameter to the brake pad tongues that hold them in the support, and strike rod with a hammer to drive brake pad out of place. (Scheme 7) CAUTION: Always replace pads for both left and right wheels at the same time. Also replace pad clips if they are twisted or worn. A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. Replace the pad if there is oil or grease on it.
5. Check pad thickness. See «FRONT DISC BRAKE SERVICE SPECIFICATIONS»(ref-162994-S02319968592004061600000) table under DISC BRAKE SPECIFICATIONS.

Scheme 6

Scheme 7

Installation

1. Apply a thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad clip.
2. Apply a thin coat of Molykote AS880N to the frictional portion between pad and pad inner shim. (Scheme 8) CAUTION: Do not allow oil or grease to adhere to the sliding surface of pad and disc rotor.
3. Check disc rotor thickness and runout. See «INSPECTION»(ref-162994-S28041806312004061600000) under FRONT DISC BRAKE ROTOR.
4. Install pads on support.
5. Install caliper body on support. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000). NOTE: If it is difficult to push the piston during pad replacement, loosen the air bleeder to facilitate work.
6. Depress brake pedal several times. Check that brake fluid level is at MAX line.
7. Install front wheel.

Scheme 8

1. Set vehicle on a lift.
2. Loosen wheel nuts.
3. Jack-up vehicle and remove front wheel.
4. Remove caliper body from housing and suspend it from the strut using a wire. (Scheme 9)
5. Remove disc rotor. NOTE: If disc rotor seizes up within the hub, drive the disc rotor out by installing an 8 mm bolt in the 2 holes on the rotor. (Scheme 10)
6. Clean mud and foreign particles from the caliper body assembly and support.

Scheme 9

Scheme 10

1. Install disc rotor.
2. Install caliper body on housing. (Scheme 9) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000).
3. Install wheel.

1. Set vehicle on a lift.
2. Loosen wheel nuts.
3. Jack-up vehicle and remove front wheel.
4. Remove union bolt and disconnect brake hose from caliper body assembly. (Scheme 11) CAUTION: Do not spill brake fluid on painted surface. Wash it off immediately.
5. Remove bolt securing lock pin to caliper body.
6. Raise caliper body and move it towards the vehicle center to separate it from support.
7. Remove support from housing. (Scheme 12) NOTE: Remove support only when replacing it or the rotor. It does not need to be removed when servicing the caliper body assembly.
8. Remove disc rotor from hub. NOTE: If disc rotor seizes up within hub, drive disc rotor out by installing an 8 mm bolt in the holes on the rotor. (Scheme 10)
9. Clean mud and foreign particles from the caliper body assembly and support.
10. Check caliper body and piston for uneven wear, damage or rust.
11. Check rubber parts for deterioration.
12. Repair or replace faulty parts.

Scheme 11

Scheme 12

1. Install disc rotor on hub.
2. Install support on housing. (Scheme 12) Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000). CAUTION: Always replace the pads for both the left and right wheels at the same time. Also, replace the pad clips if they are twisted or worn. A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. When replacing the pads, replace the pads of the right and left wheels at the same time.
3. Apply a thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad clip.
4. Apply a thin coat of Molykote AS880N to the frictional portion between pad and inner shim. (Scheme 8)
5. Install pads on support.
6. Install caliper body on support. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000).
7. Connect brake hose. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000). Replace brake hose gaskets with NEW ones.
8. Bleed air from brake system. See «BLEEDING PROCEDURES»(ref-162994-S11281425622004061600000) under BLEEDING BRAKE SYSTEM.

1. Set vehicle on a lift.
2. Loosen wheel nuts.
3. Jack-up vehicle and remove rear wheel.
4. Remove lock pin. (Scheme 13)
5. Raise caliper body. NOTE: Do not disconnect the brake hose from the caliper body.
6. Remove pad from support. (Scheme 14) NOTE: If brake pad is difficult to remove, see steps A - D under FRONT DISC BRAKE PADS.
7. Check pad thickness. See «REAR DISC BRAKE SERVICE SPECIFICATIONS»(ref-162994-S32847438122004061600000) table under DISC BRAKE SPECIFICATIONS. CAUTION: Always replace pads for both left and right wheels at the same time. Also replace pad clips if they are twisted or worn. A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. Replace the pad if there is oil or grease on it.

Scheme 13

Scheme 14

1. Apply a thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad clip. CAUTION: Do not allow oil or grease to adhere to the sliding surface of pad and disc rotor.
2. Check disc rotor thickness and runout. See «INSPECTION»(ref-162994-S01001746992004061600000) under REAR DISC BRAKE ROTOR.
3. Install pad on support. (Scheme 14)
4. Install caliper body on support. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000). NOTE: If it is difficult to push piston during pad replacement, loosen air bleeder to facilitate work.
5. Depress brake pedal several times.
6. Check that brake fluid level is at MAX line.

Removal & Installation

1. Lift vehicle and remove wheels.
2. Remove 2 mounting bolts and remove disc brake assembly. (Scheme 15)
3. Suspend disc brake assembly so that the hose is not stretched.
4. Pull down and release the parking brake.
5. Remove disc rotor. NOTE: If disc rotor is difficult to remove, try the following: Turn adjusting screw using a slot-type screwdriver until the brake shoe moves away enough from the disc rotor. (Scheme 16) If the disc rotor seizes up within hub, drive the disc rotor out by installing an 8 mm bolt in the 2 holes on the rotor. (Scheme 17)
6. To install, reverse removal order.
7. Adjust the parking brake. See «PARKING BRAKE»(ref-162994-S15317214242004061600000) under ADJUSTMENTS.

Scheme 15

Scheme 16

Scheme 17

1. Set vehicle on a lift.
2. Loosen wheel nuts.
3. Lift-up vehicle and remove wheels.
4. Disconnect brake hose from caliper body assembly. CAUTION: Do not allow brake fluid to come in contact with the vehicle body; wipe off completely if spilled.
5. Remove lock pin. (Scheme 18)
6. Raise caliper body and move it towards the vehicle center to separate it from support.
7. Remove support from back plate. NOTE: Remove support only when replacing it or the rotor. It does not need to be removed when servicing the caliper body assembly.
8. Clean mud and foreign particles from caliper body assembly and support. CAUTION: Be careful not to allow foreign particles to enter inlet at brake hose connector.
9. Check caliper body and piston for uneven wear, damage or rust.
10. Check rubber parts for deterioration.
11. Repair or replace faulty parts.

Scheme 18

1. Install disc rotor on hub.
2. Install support on back plate. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000) . CAUTION: Always replace pads for both left and right wheels at the same time. Also replace pad clips if they are twisted or worn. A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. Replace the pad if there is oil or grease on it.
3. Apply a thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad clip. CAUTION: Do not allow oil or grease to adhere to the sliding surface of pad and disc rotor.
4. Install pads on support.
5. Install caliper body on support. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000) .
6. Connect brake hose. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000) . CAUTION: The brake hose must be connected without any twist. Replace brake hose gaskets with NEW ones.
7. Bleed air from brake system. See «BLEEDING PROCEDURES»(ref-162994-S11281425622004061600000) under BLEEDING BRAKE SYSTEM.

1. Loosen wheel nuts, jack-up vehicle, support it with rigid racks, and remove the wheel.
2. Release parking brake.
3. Remove brake drum from the brake assembly. NOTE: If it is difficult to remove the brake drum, remove the adjusting hole cover from the back plate, and then turn the adjuster assembly pawls using a slot-type screwdriver until the brake shoe separates from the drum. (Scheme 19) If the brake drum is difficult to remove, drive it out by installing an 8 mm bolt into the bolt hole in the brake drum. (Scheme 20)
4. Hold the hold-down pin by securing rear of back plate with your hand. (Scheme 21)
5. Disconnect the hold-down cup from the hold-down pin by rotating the hold-down cup.
6. Disconnect the lower shoe return spring from shoes. (Scheme 22)
7. Remove the shoes one by one from the back plate with the adjuster. (Scheme 23) CAUTION: Be careful not to bend the parking brake cable excessively when removing the brake shoes.
8. Disconnect the parking brake cable from parking brake lever.
9. Measure lining thickness. See «REAR DRUM BRAKE SERVICE SPECIFICATIONS»(ref-162994-S06215687252004061600000) table under DRUM BRAKE SPECIFICATIONS.
10. If deformation or wear of back plate, shoe, and other components are notable, replace them.
11. When the shoe return spring tension is excessively weakened, replace it, taking care to identify upper and lower springs.

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

1. Clean the back plate and wheel cylinder.
2. Apply brake grease Dow Corning Molykote No. 7439 (Part No. 725191460) to the portions as indicated (Scheme 24)
3. Apply brake grease to adjusting screw and both ends of adjuster. (Scheme 25)
4. Connect upper shoe return spring to shoes.
5. Connect the parking brake cable to parking lever.
6. While positioning the shoes (one at a time) in groove on wheel cylinder, secure shoes. (Scheme 23)
7. Fix shoes by connecting hold-down cup to the hold-down pin.
8. Connect the lower shoe return spring.
9. Set the outside diameter of brake shoes less than 0.02-0.031" (0.5-0.8 mm) in comparison with the inside diameter of the brake drum.
10. Install the drum. See «REAR BRAKE DRUM»(ref-162994-S34291341352004061600000).

Scheme 24

Scheme 25

1. Loosen wheel nuts, jack-up vehicle, support it with rigid racks and remove wheel.
2. Release parking brake. NOTE: If it is difficult to remove the brake drum, remove the adjusting hole cover from the back plate, and then turn the adjuster assembly pawls using a slot-type screwdriver until the brake shoe separates from the drum. (Scheme 19) If the brake drum is difficult to remove, drive it out by installing an 8 mm bolt into the bolt hole in the brake drum. (Scheme 20)
3. Remove brake drum from brake assembly.
4. If the inside surface of the brake drum is streaked, correct the surface. If it is unevenly worn, tapered, streaked, or the outside surface of brake drum is damaged, correct or replace it.
5. Measure the drum inner diameter. (Scheme 26) See «REAR DRUM BRAKE SERVICE SPECIFICATIONS»(ref-162994-S06215687252004061600000) table under DRUM BRAKE SPECIFICATIONS.

Scheme 26

1. Set the outside diameter of brake shoes less than 0.02-0.031" (0.5-0.8 mm) in comparison with the inside diameter of brake drum.
2. Install drum.
3. Install rear wheel.

1. Loosen wheel nuts, jack-up vehicle, support it with rigid racks, and remove wheel.
2. Release parking brake.
3. Remove brake drum from brake assembly. See «REAR BRAKE DRUM»(ref-162994-S34291341352004061600000).
4. Remove brake shoe. See «REAR DRUM BRAKE SHOE»(ref-162994-S25525290162004061600000).
5. Unscrew brake hose flare nut and disconnect brake hose. (Scheme 27)
6. Disconnect ABS sensor from back plate (only for vehicles equipped with ABS).
7. Remove hub. See REAR HUB ASSEMBLY under REMOVAL & INSTALLATION in appropriate REAR AXLE SHAFTS article in DRIVELINE/AXLES.
8. Remove bolts installing back plate, and then, remove brake assembly. (Scheme 28)
9. Remove the bolts installing the wheel cylinder on the back plate and remove wheel cylinder. (Scheme 29)
10. Inspect wheel cylinder for leakage.
11. If deformation or wear of back plate, shoe, and etc., are notable, replace them.

Scheme 27

Scheme 28

Scheme 29

1. Clean back plate and wheel cylinder.
2. Install wheel cylinder on back plate and tighten bolts to specification. (Scheme 29) See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000).
3. Apply Dow Corning Molykote No. 7439 (Part No. 725191460) grease to the portions indicated. (Scheme 24)
4. Install brake assembly on housing and tighten bolts to specification for installation of the back plate. (Scheme 28) See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000).
5. Install hub. See REAR HUB ASSEMBLY under REMOVAL & INSTALLATION in appropriate REAR AXLE SHAFTS article in DRIVELINE/AXLES.
6. Connect brake hose and tighten flange nut to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000).
7. Connect ABS sensor to back plate (only for models equipped with ABS). Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000).
8. Apply Dow Corning Molykote No. 7439 grease to the adjusting screw and both ends of adjuster.
9. Install brake shoe. See «REAR DRUM BRAKE SHOE»(ref-162994-S25525290162004061600000).
10. Install brake drum. See «REAR BRAKE DRUM»(ref-162994-S34291341352004061600000).
11. After installing brake assembly, bleed air from brake line. See «BLEEDING PROCEDURES»(ref-162994-S11281425622004061600000) under BLEEDING BRAKE SYSTEM.

1. Move select lever to "P" position or gear shift lever to "1st" position, then block the wheels.
2. Disconnect the battery ground terminal from battery.
3. Remove console box. Disconnect the ground terminal from battery. Remove the console cover. Remove the shift knob (MT model) and front cover. Loosen the screws to remove the console box.
4. Disconnect the connector of parking brake switch.
5. Loosen the parking cable adjusting nut and console bracket.
6. Remove the parking brake lever. (Scheme 30)
7. Unbend the parking brake lever pawls and remove cable. (Scheme 31)
8. To install, reverse removal order. Tighten parking brake lever and the adjusting nut to specifications. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000).
9. Be sure to pass the cable through the guide inside tunnel. Be sure to adjust the lever stroke. See «LEVER ADJUSTMENT»(ref-162994-S23602602322004061600000) under PARKING BRAKE under ADJUSTMENTS.
10. While pulling the parking brake lever upward, count the notches. The lever stroke should be 7-8 notches at a force of 44 lbs. (196 N). If incorrect adjust the parking brake. See «PARKING BRAKE»(ref-162994-S15317214242004061600000) under ADJUSTMENTS.

Scheme 30

Scheme 31

1. Lift-up vehicle.
2. Remove rear tires and wheels.
3. Remove rear cushion.
4. Remove console box. Disconnect the ground terminal from battery. Remove the console cover. Remove the shift knob (MT model) and front cover. Loosen the screws to remove the console box.
5. Loosen parking cable adjusting nut and console bracket.
6. Remove parking brake lever. (Scheme 30)
7. Roll up floor mat and remove clamps. (Scheme 32)
8. Remove equalizer cover.
9. Remove inner cable end from equalizer. (Scheme 33)
10. Pull out parking brake cable from rear brake. See one of the following accordingly: See «PARKING BRAKE ASSEMBLY (REAR DISC BRAKE)»(ref-162994-S19145767142004061600000). See «REAR DRUM BRAKE ASSEMBLY»(ref-162994-S08870541782004061600000).
11. Pull out clamp from rear brake.
12. Remove bolt and bracket from trailing link bracket.
13. Remove bolt and clamp from rear floor. (Scheme 34)
14. Detach grommet from rear floor.
15. Remove cable assembly from cabin by forcibly pulling it backward.
16. Detach parking brake cable from cable guide at rear trailer link.
17. Inspect parking brake cable and replace it id damaged, rusty or malfunctioning: Check that cable operates smoothly. Check inner cable for damage and rust. Check outer cable for damage, bends or cracks. Check boot for damage, cracks or deterioration.
18. Install NEW parking brake assembly in reverse order of removal.
19. Be sure to pass cable through the cable guide inside tunnel. Adjust the lever stroke. See «LEVER ADJUSTMENT»(ref-162994-S23602602322004061600000) under PARKING BRAKE under ADJUSTMENTS.

Scheme 32

Scheme 33

Scheme 34

1. Set vehicle on a lift.
2. Disconnect ground terminal from battery.
3. Loosen wheel nuts.
4. Jack-up vehicle and remove wheel.
5. Remove 2 mounting bolts and remove disc brake assembly. (Scheme 15)
6. Suspend disc brake assembly so that the hose is not stretched.
7. Pull down and release the parking brake.
8. Remove disc rotor. NOTE: If the disc rotor is difficult to remove, perform the following procedures: Turn the adjusting screw using a slot-type screw driver until the brake shoe gets away enough from the disc rotor. (Scheme 16) If disc rotor seizes up within the hub, drive the disc rotor out by installing an 8 mm bolt in the side holes on the rotor. (Scheme 17)
9. Remove the primary and secondary return spring from the parking brake assembly.
10. Remove the front shoe hold down spring and pin with pliers.
11. Remove strut and strut spring.
12. Remove adjuster assembly and adjusting spring from the parking brake assembly.
13. Remove brake shoe.
14. Remove rear shoe hold down spring and pin with pliers. (Scheme 35)
15. Remove parking cable from parking lever. (Scheme 36)
16. Using a standard screwdriver, raise the retainer. Remove the parking lever and washer from the brake shoe.
17. Measure the brake disc inside diameter. See «REAR DISC BRAKE SERVICE SPECIFICATIONS»(ref-162994-S32847438122004061600000) table under DISC BRAKE SPECIFICATIONS. If the disc is scored or worn, replace the brake disc.
18. Measure the lining thickness. See «REAR DISC BRAKE SERVICE SPECIFICATIONS»(ref-162994-S32847438122004061600000) table under DISC BRAKE SPECIFICATIONS. If it exceeds the limit, replace the shoe assembly.

Scheme 35

Scheme 36

1. Apply Dow Corning Molykote No. 7439 (Part No. 725191460) brake grease to the following places: The 6 contact surfaces of shoe rim and back plate packing. Contact surface of shoe wave and anchor pin. Contact surface of lever and strut. Contact surface of shoe wave and adjuster assembly. Contact surface of shoe wave and strut. Contact surface of lever and shoe wave.
2. Install components in the reverse order of removal. CAUTION: Use NEW retainers and clinch them when installing the brake shoes to levers. Ensure that the parking lever moves smoothly. Do not confuse the left parking lever with the right one. Do not confuse left strut with right one. NOTE: Ensure that the adjuster assembly is securely installed with the screw in the left side, facing the vehicle front. (Scheme 37) Ensure that the shoe return spring is installed as shown. (Scheme 38)
3. Adjust the parking brake. See «PARKING BRAKE»(ref-162994-S15317214242004061600000) under ADJUSTMENTS. NOTE: After replacing the parking brake lining, be sure to drive the vehicle for "break-in" purposes.
4. Drive the vehicle at 22 MPH.
5. With the parking brake release button pushed in, pull the parking brake lever gently.
6. Drive the vehicle for about 0.12 mile (200 meters) in this condition.
7. Wait 5 to 10 minutes for the parking brake to cool down. Repeat this procedure once more.
8. After breaking-in, re-adjust the parking brakes.

Scheme 37

Scheme 38

1. Pull up parking brake lever, and block the tires.
2. Disconnect ground cable from battery.
3. Thoroughly drain brake fluid from reservoir tank.
4. Disconnect fluid level indicator harness connector.
5. Remove brake pipes from master cylinder.
6. Remove master cylinder mounting nuts, and take master cylinder out from brake booster. CAUTION: Do not spill brake fluid. Brake fluid spilt on vehicle body will harm the painted surface; wipe it off quickly if spilt.
7. To install, reverse removal procedures. Tighten the master cylinder mounting nut and the piping flare nut to specifications. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000) . CAUTION: Be sure to use recommended brake fluid. See «BRAKE FLUID»(ref-162994-S24412324762004061600000) under BLEEDING BRAKE SYSTEM.
8. Bleed air from the brake system. See «BLEEDING PROCEDURES»(ref-162994-S11281425622004061600000) under BLEEDING BRAKE SYSTEM.

1. Remove or disconnect the following parts at the engine compartment: Disconnect the connector for brake fluid level indicator. Remove brake pipes from the master cylinder. Remove the master cylinder installing nuts. Disconnect vacuum hose from the brake booster.
2. Remove the following parts from the pedal bracket: Remove snap pin and clevis pin. Remove four brake booster installing nuts. CAUTION: If external force is applied from above when brake booster is placed on its side, the resin portion may be damaged. (Scheme 39) NOTE: Be careful not to drop the brake booster. Brake booster should be discarded if it has been dropped. Use special care when handling the operating rod. If excessive force is applied to the operating rod, sufficient to cause a change in the angle in excess of 3 degrees, it may result in damage to the power piston cylinder. NOTE: Use care when placing the brake booster on the floor. Do not change the push rod length. If it has been changed, reset the projected length to the standard length. (Scheme 40) See «PUSH ROD SPECIFICATIONS»(ref-162994-S41555201072004061600000) table.
3. Remove the brake booster while shunning brake pipes.

Scheme 39

Scheme 40

BRAKE BOOSTER SPECIFICATIONS

1. Mount the brake booster in position.
2. Connect the operating rod to the brake pedal with the clevis pin and the snap pin. (Scheme 41)
3. Connect the vacuum hose to the brake booster. (Scheme 42)
4. Mount the master cylinder onto brake booster.
5. Connect the brake pipes to the master cylinder.
6. Connect the electric connector for brake fluid level indicator.
7. Adjust the operating rod of the brake booster. (Scheme 43) If it is not to specified length, adjust it by adjusting the brake booster operating rod. See «BRAKE BOOSTER SPECIFICATIONS»(ref-162994-S41555201072004061600000) table.
8. Measure the clearance between threaded end of stop light switch and stopper. If stop light switch clearance is not 0.012" (0.3 mm), adjust it by adjusting the position of the stop light switch. (Scheme 44) CAUTION: Do not rotate the stop light switch.
9. Apply grease to operating rod connecting pin to prevent it from wearing.
10. Bleed air from brake system. Tighten air bleeder screw to specification. See «TORQUE SPECIFICATIONS»(ref-162994-S28577697282004061600000).
11. Conduct road tests to ensure brakes do not drag.

Scheme 41

Scheme 42

Scheme 43

Scheme 44