Disc & Drum: Overhaul Subaru Outback BP

REAR DISC BRAKE ASSEMBLY

FRONT DISC BRAKE ASSEMBLY

Note. Before disassembling and reassembling front disc brake assembly, identify the brakes components. (Scheme 32)

Scheme 32

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. Place a wooden block as shown to prevent damage to piston. (Scheme 33) Gradually supply compressed air via caliper body brake hose to force piston out.
4. Remove the piston seal from the caliper body cylinder. (Scheme 34)
5. Remove the lock pin boot and guide pin boot. NOTE: Repair or replace faulty parts.
6. Check caliper body and piston for uneven wear, damage or rust.
7. Check the rubber parts for damage or deterioration.

Scheme 33

Scheme 34

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. K07779GA102) grease to the boot and fit in the groove on ends of cylinder and piston.
5. Insert piston into cylinder. (Scheme 35) CAUTION: Do not force piston into cylinder.
6. Position boot in grooves on cylinder and piston. (Scheme 36)
7. Apply a coat of NIGLUBE RX-2 grease to lock pin and guide pin, outer surface, cylinder inner surface, and boot grooves. (Scheme 37)
8. Install lock pin boot and guide pin boot on support.

Scheme 35

Scheme 36

Scheme 37

Note. Before disassembling and reassembling rear disc brake assembly, identify the brakes components. (Scheme 38)

Scheme 38

1. Remove boot ring. (Scheme 39)
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 33) Do not apply excessively high pressure.
4. Remove piston seal from caliper body cylinder.
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 39

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. 003606000) 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 36)
7. Apply a coat of NIGLUBE RX-2 grease to guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves. (Scheme 37)
8. Install guide pin boot on caliper body.
9. Install the lock pin boot on caliper body and insert lock pin sleeve into place.

MASTER CYLINDER ASSEMBLY

Note. Before disassembling and reassembling master cylinder assembly, identify the master cylinder components. (Scheme 40)or (Scheme 41).

Scheme 40

Scheme 41

1. Remove mud and dirt from the surface of the brake master cylinder.
2. Prepare the tools necessary for disassembly operation, and arrange them neatly on work bench.
3. Clean the work bench.
4. Remove the pin with drift pin which secures the reserve tank to master cylinder.
5. Remove the cylinder pin with magnetic pick-up tool while pushing in primary piston. (Scheme 42)
6. Pry up the pawl and remove the piston retainer (models not equipped with VDC). (Scheme 43) NOTE: Piston may jump out from master cylinder.
7. Using pliers, remove "C" ring (models equipped with VDC). (Scheme 44) NOTE: Piston may jump out from master cylinder.
8. Extract the primary piston assembly and secondary piston assembly. CAUTION: Do not disassemble the piston assembly; otherwise, the spring set value may be changed. Use brake fluid or methanol to wash inside wall of cylinder, piston and piston cups. Be careful not to damage parts when washing. If methanol is used for washing, do not dip rubber parts, such as piston cups, in it for more than 30 seconds; otherwise, they may become swelled.
9. 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 42

Scheme 43

Scheme 44

1. When assembling, be sure to use recommended brake fluid. See «BRAKE FLUID»(ref-163893-S34553124582004071500000) under BLEEDING BRAKE SYSTEM.
2. Ensure that the inside wall of cylinder, pistons, and piston cups are free from dirt when assembling.
3. Be extremely careful not to damage, scratch, or dent cylinder inside wall, pistons, and piston cups.
4. Do not drop the parts. Never attempt to use any part that has been dropped accidentally.
5. To assemble the piston assembly, apply recommended brake fluid to inside wall of cylinder and to outer surface of piston assembly, and install the piston assemblies carefully into cylinder.
6. To assemble the cylinder pin, perform the following procedures: Press the pawl and install the piston retainer into the master cylinder (models not equipped with VDC). (Scheme 43) Using pliers, install "C" ring in its groove (models equipped with VDC). (Scheme 44) CAUTION: Make sure to install it firmly to groove. Install the seal to reservoir tank. (Scheme 45) Install the pin with drift pins which secures the reservoir tank to master cylinder.

Scheme 45