Disc & Drum: Overhaul Subaru Forester SG

REAR DISC BRAKE ASSEMBLY

REAR DRUM BRAKE ASSEMBLY

FRONT DISC BRAKE ASSEMBLY

Note. Before disassembling and reassembling front disc brake assembly, identify the brakes components. (Scheme 48)

Scheme 48

Disassembly

1. Clean mud and foreign particles from the caliper body assembly and support. CAUTION: Be careful not to allow foreign particles to enter inlet at brake hose connector.
2. Remove the boot from the piston end.
3. Gradually supply compressed air via caliper body brake hose to force piston out. CAUTION: Place a wooden block as shown to prevent damage to piston. (Scheme 49)
4. Remove the piston seal from the caliper body cylinder. (Scheme 50)
5. Remove the lock pin boot and guide pin boot.
6. Repair or replace faulty parts.
7. Check caliper body and piston for uneven wear, damage or rust.
8. Check the rubber parts for damage or deterioration.

Scheme 49

Scheme 50

Assembly

1. Clean the caliper body Interior using brake fluid.
2. Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.
3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.
4. Apply a coat of NIGLUBE RX-2 (Part No. K0779GA102) grease to the boot and fit in the groove on ends of cylinder and piston. To facilitate installation, fit the boot starting with the piston end. (Scheme 52)
5. Insert piston into cylinder. (Scheme 51) CAUTION: Do not force piston into cylinder.
6. Position boot in grooves on cylinder and piston.
7. Apply a coat of NIGLUBE RX-2 grease to lock pin and guide pin, outer surface, cylinder inner surface, and boot grooves. (Scheme 53)
8. Install lock pin boot and guide pin boot on support.

Scheme 51

Scheme 52

Scheme 53

Note. Before disassembling and reassembling rear disc brake assembly, identify the brakes components. (Scheme 54)

Scheme 54

1. Remove boot ring. (Scheme 55)
2. Remove piston boot.
3. Gradually supply compressed air via inlet of caliper body to force piston out. CAUTION: Place a wooden block as shown to prevent damage to piston. (Scheme 49) Do not apply excessively high pressure.
4. Remove piston seal from caliper body cylinder. CAUTION: Be careful not to scratch the inner surface of cylinder and piston seal groove.
5. Remove lock pin sleeve and boot from caliper body.
6. Remove guide pin boot. NOTE: Repair or replace faulty parts.
7. Check caliper body and piston for uneven wear, damage or rust.
8. Check the rubber parts for damage or deterioration.

Scheme 55

1. Clean caliper body interior using brake fluid.
2. Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.
3. Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.
4. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder.
5. Apply a coat of NIGLUBE RX-2 (Part No. K0779GA102) grease to the boot and fit in the groove on ends of cylinder and piston.
6. Install the piston boot to the caliper body, and attach boot ring. (Scheme 52)
7. Apply a coat of NIGLUBE RX-2 grease to guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves. (Scheme 53)
8. Install guide pin boot on support.
9. Install the lock pin boot on support and insert lock pin sleeve into place.

Note. Before disassembling and reassembling rear drum brake assembly, identify the brakes components. (Scheme 56)

Scheme 56

1. Remove right and left dust boots from wheel cylinder. (Scheme 57)
2. Remove the piston, cup, spring and air bleeder screw and cap.
3. Inspect the wheel cylinder for leakage.
4. If deformation or wear of back plate, shoe, and other components are notable, replace them.

Scheme 57

1. Clean all parts with brake fluid. Check and replace faulty parts. Check cup and boot for damage or fatigue. Check cylinder, piston and spring for damage or rust formation.
2. Assemble parts in reverse order of disassembly. When installing the cup, use ST, apply brake fluid to the frictional surface for smooth installation and pay attention to cup direction. (Scheme 58) ST's are available in different sizes. Use only the 3/4" (19 mm) ST adapter tool (Part No. 926460000). CAUTION: When replacing the repair kit, make sure that the sizes of cylinder and cup are the same as those which were replaced. While assembling, be careful to prevent any metal chip, dust or dirt from entering the wheel cylinder.
3. Apply NIGLUBE RX-2 (Part No. K0779GA102) rubber grease to the boot inside as shown. (Scheme 59) CAUTION: Never use brake grease.

Scheme 58

Scheme 59

MASTER CYLINDER ASSEMBLY

Note. Before disassembling and reassembling master cylinder assembly, identify the master cylinder components. (Scheme 60)

Scheme 60

1. Remove mud and dirt from the surface of the brake master cylinder.
2. Secure the master cylinder on a vise.
3. Remove the pin with drift pin which secures the reserve tank to master cylinder and remove the reservoir tank and grommet.
4. Remove the cylinder pin with magnetic pick-up tool while pushing in primary piston with a screwdriver that is wrapped in tape. (Scheme 61)
5. Pry up the pawl and remove the piston retainer. (Scheme 62) NOTE: Hold piston retainer tight, because the piston may jump out from master cylinder.
6. Extract the primary piston assembly and secondary piston assembly straight out, while taking care not to scratch the inner surface of the cylinder.
7. Use brake fluid to wash the inside wall of the cylinder and the piston assembly.
8. If any damage, deformation, wear, swelling, rust, and other faults are found on the primary piston assembly, secondary piston assembly, supply valve stopper, or gasket, replace the faulty part. CAUTION: The primary and secondary pistons must be replaced as complete assemblies. The service limit of the clearance between each piston and the master cylinder inner diameter is 0.0043" (0.11 mm). When handling parts, be extremely careful not to damage or scratch the parts, or let any foreign matter get on them.

Scheme 61

Scheme 62

1. Apply recommended brake fluid to the inside wall of cylinder and to the outer surface of the piston assembly. See «BRAKE FLUID»(ref-163288-S20321301372004062400000) under BLEEDING BRAKE SYSTEM.
2. Ensure that the inside wall of cylinder, pistons, and piston cups are free from dirt when assembling.
3. Install primary piston and secondary piston assembly. CAUTION: Be extremely careful not to damage, scratch, or dent cylinder inside wall, pistons, and piston cups.
4. Install the cylinder pin while pushing in primary piston with a tape wrapped screwdriver.
5. Install the piston retainer into the master cylinder and press the pawl to secure it in place. (Scheme 62)
6. Install the reservoir tank to master cylinder and secure with pin. (Scheme 63)

Scheme 63