Brake System: Removal & Installation Subaru Forester SH рестайлинг

INSTALLATION

1. Install the disc rotor.
2. Install the caliper body assembly to the housing. Tightening torque: 80 N.m (8.16 kgf-m, 59.0 ft-lb)
3. Install the front wheels.

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1. Check the front wheel bearing play and axle hub runout before the inspection of disc rotor runout limit. < Ref. to «INSPECTION»(ref-465404-S24352578452012042000000) , Front Axle . >
2. Secure the disc rotor by tightening the five wheel nuts.
3. Set a dial gauge 10 mm (0.39 in) inward from the disc rotor outer circumference. Rotate the disc rotor to check runout. If the disc rotor runout exceeds the limit, resurface the disc rotor. After grinding, check the thickness of the disc rotor according to the procedure in step 4 ). Disc rotor runout limit: 0.05 mm (0.0020 in)
4. Set a micrometer 10 mm (0.39 in) inward from the disc rotor outer perimeter, and then measure the disc rotor thickness. If the disc rotor thickness (A) exceeds the service limit, replace with a new disc rotor. DISC ROTOR DIAMETER REFERENCE CHART Standard Limit Disc rotor diameter Disc rotor thickness A mm (in) 24 (0.94) 22 (0.87) 294 (11.57)

REMOVAL

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1. Lift up the vehicle, and then remove the front wheels.
2. Remove the union bolt, and disconnect the brake hose from the caliper body.
3. Remove the bolts which secure the caliper body.
4. Raise the caliper body, and then move it toward vehicle center to separate it from the support.
5. Remove the brake pad, and then remove the support from the housing. NOTE: Remove the support only when replacing the rotor or support. It is not necessary to remove it when servicing the caliper body.
6. Remove mud and foreign matter from the caliper body and the support.

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1. Apply a thin coat of Molykote M7439 (Part No. K0770YA000) or grease contained in the pad kit to the support.
2. Install the support to the housing. Tightening torque: 80 N.m (8.16 kgf-m, 59.0 ft-lb)
3. Apply a thin coat of Molykote M7439 (Part No. K0770YA000) or grease contained in the pad kit to the pad clip.
4. Apply a thin coat of Molykote AS880N (Part No. K0777YA010) or grease contained in the pad kit to both surfaces of the pad inner shim.
5. Install the pad to support. CAUTION: Be sure to install so that the pad return spring faces the input side of the direction of brake rotor rotation, as shown in the illustration. Correctly install the pad return spring to the supporting surface of the pad clip as shown in the illustration. If the pad return spring is deformed or damaged, replace the brake pad. NOTE: Install the pad indicator in proper direction.
6. Install the caliper body to the support. Tightening torque: 27 N.m (2.75 kgf-m, 19.9 ft-lb)
7. Connect the brake hose using a new brake hose gasket. Tightening torque: 18 N.m (1.84 kgf-m, 13.3 ft-lb)
8. Bleed air from the brake system. < Ref. to «PROCEDURE»(ref-465400-S28290080402012042000000) , Air Bleeding . >

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1. Remove mud and foreign matter from the caliper body and the support. CAUTION: Be careful not to allow foreign matter to enter the brake hose connector.
2. Place a wooden block in the caliper body as shown in the illustration to prevent the piston from jumping out and being damaged.
3. Gradually apply compressed air via the brake hose installation hole to push the piston out.
4. Remove the piston boot.
5. Remove the piston seal (1) from the caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove.
6. Position the boot in the grooves on cylinder and piston.

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1. Clean the inside of the caliper body using brake fluid.
2. Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body groove.
3. Apply a coat of brake fluid to the inner surface of cylinder and the entire outer surface of the piston.
4. Apply NIGLUBE RX-2 (Part No. 000041000) or grease contained in the piston seal kit to the boot, and install it to the groove at the end of the cylinder.
5. Insert the piston into cylinder. CAUTION: Do not force the piston into cylinder.
6. Remove the guide pin and boot from caliper body.
7. Apply NIGLUBE RX-2 (Part No. 000041000) or grease contained in the piston seal kit to the lock pin, guide pin outer surface, cylinder inner surface, and boot grooves.
8. Insert the lock pin and guide pin boot into the support. CAUTION: Insert the lock pin and guide pin into specified position, and make sure that they slide and seat properly.

1. Install each part in the reverse order of removal. Tightening torque: Brake hose bracket 33 N.m (3.36 kgf-m, 24.3 ft-lb) Caliper body assembly 66 N.m (6.73 kgf-m, 48.7 ft-lb)
2. Adjust the parking brake. < Ref. to «ADJUSTMENT»(ref-465401-S22560082622012042000000) , Parking Brake Assembly (Rear Disc Brake) . >

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1. Check the rear wheel bearing play and axle hub runout before inspecting the disc rotor runout. < Ref. to «INSPECTION»(ref-465404-S36924237462012042000000) , Rear Hub Unit Bearing . >
2. Secure the disc rotor by tightening the five wheel nuts.
3. Set a dial gauge 10 mm (0.39 in) inward from the disc rotor outer circumference. Rotate the disc rotor to check runout. If the disc rotor runout exceeds the limit, resurface the disc rotor. After grinding, check the thickness of the disc rotor according to the procedure in step 4 ). Disc rotor runout limit: 0.05 mm (0.0020 in)
4. Set a micrometer 10 mm (0.39 in) inward from the disc rotor outer perimeter, and then measure the disc rotor thickness. If the thickness A of the disc rotor exceeds the service limit, replace with a new disc rotor. DISC ROTOR DIAMETER REFERENCE CHART Standard Limit Disc rotor diameter Disc rotor thickness A mm (in) 10 (0.39) 8.5 (0.335) 286 (11.26)

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1. Lift up the vehicle, and then remove the rear wheels.
2. Remove the brake hose bracket.
3. Disconnect the brake hose.
4. Remove the caliper bolt.
5. Raise the caliper body, and then move it toward vehicle center to separate it from the support.
6. Remove the brake pad, and then remove the support from the housing. NOTE: Remove the support only when replacing the rotor or support. It is not necessary to remove it when servicing the caliper body.
7. Remove mud and foreign matter from the caliper body and the support. CAUTION: Be careful not to allow foreign matter to enter the brake hose connector.

1. Apply a thin coat of Molykote M7439 (Part No. K0770YA000) or grease contained in the pad kit to the support.
2. Install the support to the housing. Tightening torque: 66 N.m (6.73 kgf-m, 48.7 ft-lb)
3. Apply a thin coat of Molykote M7439 (Part No. K0770YA000) or grease contained in the pad kit to the pad clip.
4. Apply a thin coat of Molykote AS880N (Part No. K0777YA010) or grease contained in the pad kit to the contact surface between the pad and shim.
5. Apply a thin coat of Molykote AS880N (Part No. K0777YA010) or grease contained in the pad kit to both surfaces of the pad inner shim.
6. Install the pad to support.
7. Install the caliper body to the support. Tightening torque: 27 N.m (2.75 kgf-m, 19.9 ft-lb)
8. Install the brake hose bracket. Tightening torque: 33 N.m (3.36 kgf-m, 24.3 ft-lb)
9. Connect the brake hose using a new brake hose gasket. Tightening torque: 18 N.m (1.84 kgf-m, 13.3 ft-lb)
10. Bleed air from the brake system. < Ref. to «PROCEDURE»(ref-465400-S28290080402012042000000) , Air Bleeding . >

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1. Remove the piston boot.
2. Place a wooden block in the caliper body as shown in the illustration to prevent the piston from jumping out and being damaged.
3. Gradually apply compressed air via the brake hose installation hole to push the piston out.
4. Remove the piston seal from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove.
5. Remove the pin boot.

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1. Clean the inside of the caliper body using brake fluid.
2. Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body groove.
3. Apply a coat of brake fluid to the inner surface of cylinder and the entire outer surface of the piston.
4. Apply NIGLUBE RX-2 (Part No. 000041000) or grease contained in the piston kit to the boot, and install it to the groove at the end of the cylinder.
5. Insert the piston into the cylinder. CAUTION: Do not force the piston into cylinder.
6. Position the boot in the grooves on piston and cylinder.
7. Apply NIGLUBE RX-2 (Part No. 000041000) or grease contained in the piston kit to cylinder inner surface, pin, bushing outer surface, and boot grooves.
8. Insert the pin boot into the support.
9. Install the pin boot to the support, and then insert the pin into the specified position. CAUTION: Insert pin into position, and make sure that it slides and seats properly.

1. Drain brake fluid from the reservoir tank completely.
2. Disconnect the harness connector of the fluid level gauge.
3. Remove the brake pipe from the master cylinder.
4. Remove the master cylinder mounting nuts, and carefully remove the master cylinder from the brake booster.

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1. Replace the O-ring for the master cylinder with a new part. CAUTION: Be careful not to install the O-ring in the wrong location.
2. Install each part in the reverse order of removal. Tightening torque: Master cylinder mounting nut 13 N.m (1.33 kgf-m, 9.6 ft-lb) Piping flare nut 19 N.m (1.94 kgf-m, 14 ft-lb) CAUTION: Be sure to use recommended brake fluid.
3. Bleed air from the brake system. < Ref. to «PROCEDURE»(ref-465400-S28290080402012042000000) , Air Bleeding . >

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1. Remove mud and dirt from the surface of brake master cylinder.
2. Secure the master cylinder in a vise. CAUTION: To avoid damaging the master cylinder, place between aluminum plates or other material when holding with a vise.
3. Remove the pin which secures the master cylinder and reservoir tank, then remove the reservoir tank and seal.
4. While pushing in the primary piston, remove the C-ring using pliers.
5. While pushing in the primary piston, remove the cylinder pin (1) from the port on the reservoir tank attachment location using a magnet pick-up tool.
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. Clean the inside of master cylinder with brake fluid. Check the inside of the cylinder for damage, deformation and wear. Replace the master cylinder as an assembly if faulty.
8. Apply brake fluid to the inner surface of master cylinder and piston assembly.
9. Make sure that the inner surface of master cylinder and the piston assembly are free of foreign matter. Install the primary piston assembly and the secondary piston assembly to master cylinder, while taking care not to scratch the master cylinder inner surface.
10. While pushing-in the primary piston, install the cylinder pin.
11. While pushing-in the primary piston, install the C-ring to the groove using pliers. CAUTION: Make sure the C-ring is installed to the groove securely.
12. Install the seal (1) to reservoir tank.
13. Install the reservoir tank to the master cylinder, and secure with pin.
14. Replace the O-ring for the master cylinder with a new part.

REPLACEMENT

Note. During the operation, keep the reservoir tank filled with brake fluid to prevent entry of air. Operate the brake pedal slowly. For convenience and safety, perform the work with 2 people. The required amount of brake fluid is approximately 500 m fi (16.9 US fl oz, 17.6 Imp fl oz) for the entire brake system.

1. Lift up the vehicle and set rigid racks at the specified locations, or keep the vehicle lifted.
2. Remove both the front and rear wheels.
3. Drain brake fluid from the reservoir tank.
4. Refill the reservoir tank with recommended brake fluid. Recommended brake fluid: Refer to the " «SPECIFICATIONS»(ref-465400-S16693583142012042000000) " . < Ref. to «SPECIFICATION»(ref-465400-S16693583142012042000000) , General Description . > Perform the same procedure as for bleeding the brake line, until new brake fluid comes out from vinyl tube. < Ref. to «PROCEDURE»(ref-465400-S28290080402012042000000) , Air Bleeding . >

Note. The airbag system wiring harness is routed near the center brake pipe.

Note. The airbag system wiring harness is routed near the center brake pipe.

Brake pipe tightening torque

Refer to COMPONENT .

Front brake pipes & hoses: < Ref. to FRONT BRAKE PIPES AND HOSES , COMPONENT, General Description . > Center and rear brake pipes & hoses: < Ref. to CENTER AND REAR BRAKE PIPES & HOSES , COMPONENT, General Description . >