Brake System: Other Subaru Forester SJ

CAUTION

1. Wear appropriate work clothing, including a helmet, protective goggles and protective shoes when performing any work.
2. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
3. Use SUBARU genuine grease etc. or equivalent. Do not mix grease etc. of different grades or manufacturers.
4. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth between the part and the vise.
5. Be sure to tighten fasteners including bolts and nuts to the specified torque.
6. Place shop jacks or rigid racks at the specified points.

Scheme 123

Scheme 124

1. Lift up the vehicle, and then remove the front wheels.
2. Remove the front brake pad. Remove the caliper bolt on the lower side. Raise the caliper body assembly and support it. NOTE: Do not disconnect the brake hose from the caliper body assembly. Remove the brake pad from support - front disc brake.

PROCEDURE

MASTER CYLINDER

Note. When the master cylinder assembly is replaced or the reservoir tank is empty, bleed the brake master cylinder and the clutch master cylinder (MT model). If bleeding of the master cylinder assembly is not necessary, omit the following procedures, and perform bleeding of the brake line. < Ref. to BRAKE LINE , PROCEDURE, Air Bleeding. >

Scheme 125

Scheme 126

1. Add the brake fluid to the reservoir tank of the master cylinder assembly. NOTE: MT model: Add the brake fluid until it flows out from the clutch hose nipple. Except for MT model: Add the brake fluid up to the "MAX" level. While bleeding air, keep the reservoir tank filled with brake fluid at MIN level or higher to prevent entry of air.
2. Disconnect the brake line at primary and secondary sides.
3. Wrap the master cylinder assembly with a plastic bag.
4. Depress the brake pedal slowly and hold it.
5. Plug the outlet plug with your finger, and then release the brake pedal.
6. Repeat the step 4 ) and 5 ) several times.
7. Remove the plastic bag.
8. Turn and tighten the flare nut (b) by hand while pressing the brake pipe (a) toward the master cylinder assembly side. CAUTION: Be careful not to make scratches or other damage to the inside surface of the brake pipe flare. Tightening torque: Brake pipe flare nut: 19 N.m (1.94 kgf-m, 14.0 ft-lb)
9. Bleed air from the brake line. < Ref. to «BRAKE LINE»(ref-662128-S20030420092014101300000) , PROCEDURE, Air Bleeding. >

Scheme 127

Scheme 128

1. When the master cylinder assembly is replaced or the reservoir tank is empty, bleed the master cylinder assembly before bleeding the brake line. < Ref. to «MASTER CYLINDER»(ref-662128-S27208397122014101300000) , PROCEDURE, Air Bleeding. >
2. Fill the reservoir tank of the master cylinder assembly with brake fluid. NOTE: While bleeding air, keep the reservoir tank filled with brake fluid to prevent entry of air.
3. Attach one end of the vinyl tube to the bleeder - screw and the other end to the brake fluid container.
4. Depress the brake pedal several times, and hold it.
5. Loosen the bleeder - screw to drain brake fluid. Tighten the bleeder - screw quickly, and release the brake pedal.
6. Repeat the steps 4 ) to 5 ) until there are no more air bubbles in the vinyl tube.
7. Repeat the steps from 2 ) to 6 ) above to bleed air from each wheel. NOTE: Perform air bleed starting in the order from the farthest wheel cylinder from the master cylinder assembly.
8. Securely tighten the bleeder - screw. Tightening torque: Bleeder - screw: 8 N.m (0.82 kgf-m, 5.9 ft-lb)
9. Check that there are no brake fluid leaks in the entire brake system.
10. Check the pedal stroke. Warm up the engine until the engine speed stabilizes. Depress and hold the brake pedal with a force of 500 N (51 kgf, 112 lbf). Adjust the tilt position of the steering wheel to the lowest position. Measure the distance between brake pedal and steering wheel. Release the pedal, and measure the distance between pedal and steering wheel again. Specification of pedal stroke: 110 mm (4.33 in) or less when depressing the pedal with a force of 500 N (51 kgf, 112 lbf)
11. If the distance is more than specification, there is a possibility of air being caught in the brake line. Bleed the brake line of all air until the pedal stroke meets the specification.
12. Operate the hydraulic control unit in the sequence control mode. < Ref. to «ABS SEQUENCE CONTROL»(ref-662135-S24997258552014101300000) . >
13. Check the pedal stroke again.
14. If the distance is more than specification, there is a possibility of air being caught in the hydraulic unit. Repeat above steps 2 ) to 9 ) until the pedal stroke meets the specification.
15. Fill the reservoir tank with brake fluid up to the "MAX" level.
16. Perform a road test and ensure that the brakes operate normally.

Scheme 129

1. Separate the brake pipe (b) from brake hose (a) using a flare nut wrench.
2. Remove the clamp, strut mounting bolt and union bolt, and remove the front brake hose.

Scheme 130

1. Remove the brake hose bracket bolt and union bolt.
2. Press and separate the brake pipe (a) using a flare nut wrench.
3. Remove the brake hose clamp (b), and remove the rear brake hose (c).

FRONT BRAKE HOSE

1. Secure the brake hose to strut mount. Tightening torque: Brake hose: 33 N.m (3.36 kgf-m, 24.3 ft-lb)
2. Connect the brake hose to the front caliper body assembly using a new gasket. Tightening torque: Union bolt: 18 N.m (1.84 kgf-m, 13.3 ft-lb)
3. Position the disc in straight position and route the brake hose through the hole in the bracket on the wheel apron side. CAUTION: Do not twist the brake hose.
4. Temporarily tighten the flare nut which connects brake pipe and hose.
5. Secure the brake hose to wheel apron bracket with clamp.
6. Turn and tighten the flare nut (b) by hand while pressing the brake pipe (a) toward the master cylinder assembly side. CAUTION: Be careful not to make scratches or other damage to the inside surface of the brake pipe flare. Tightening torque: Brake pipe flare nut: 19 N.m (1.94 kgf-m, 14.0 ft-lb)
7. Bleed air from the brake system. < Ref. to «PROCEDURE»(ref-662128-S34945780212014101300000) , Air Bleeding. >

REAR BRAKE HOSE

1. Route the brake hose through the hole of bracket, and lightly tighten the flare nut to connect brake pipe.
2. Insert the clamp to secure brake hose. Tightening torque: Brake hose bracket: 33 N.m (3.36 kgf-m, 24.3 ft-lb)
3. Install the brake hose to rear caliper body using a new gasket. Tightening torque: Union bolt: 18 N.m (1.84 kgf-m, 13.3 ft-lb)
4. Tighten the flare nut to the specified torque. Tightening torque: Brake pipe flare nut: 15 N.m (1.53 kgf-m, 11.1 ft-lb)
5. Bleed air from the brake system. < Ref. to «PROCEDURE»(ref-662128-S34945780212014101300000) , Air Bleeding. >

MT MODEL

Note. Brake pedal is integrated with the clutch pedal.

For removal procedures of the brake pedal, refer to Clutch section. < Ref. to REMOVAL , Clutch Pedal. >

BRAKE VACUUM PUMP

Install in the reverse order of removal.

Tightening torque

Bracket - generator: 19 N.m (1.9 kgf-m, 14.0 ft-lb)

Vacuum pump assembly: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)

Refer to "Read Diagnostic Trouble Code (DTC)" of "BRAKE VACUUM CONTROL". < Ref. to OPERATION , Read Diagnostic Trouble Code (DTC). >

VACUUM HOSE

Check to see that air only flows in one direction, when air is blown into or sucked from the hose.

NOTE

Scheme 131