Disc & Drum: Removal & Installation Subaru Outback BP

Removal

1. Set vehicle on a lift.
2. Loosen wheel nuts.
3. Jack-up vehicle and remove front wheel.
4. Remove lock pin.
5. Raise caliper body.
6. 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.
7. Check pad thickness. See «DISC BRAKE SPECIFICATIONS»(ref-163893-S07595305762004071500000).

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)
3. Install pads on support.
4. Install caliper body on support. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163893-S42052495442004071500000). NOTE: If it is difficult to push the piston during pad replacement, loosen the air bleeder to facilitate work.
5. Install front wheel.

Scheme 8

1. Remove the brake pad. See «FRONT DISC BRAKE PADS»(ref-163893-S31806271132004071500000).
2. Remove the support. (Scheme 9) NOTE: Remove support only when replacing it or the rotor. It does not need to be removed when servicing the caliper body assembly.
3. 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)
4. Clean mud and foreign particles from the caliper body assembly and support.

Scheme 9

Scheme 10

1. Install disc rotor.
2. Install support. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163893-S42052495442004071500000) . CAUTION: Always replace pads for both the 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.
3. Install pads and caliper body. See «FRONT DISC BRAKE PADS»(ref-163893-S31806271132004071500000) .

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)
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 9) 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 the hub, drive the disc rotor out by installing an 8 mm bolt in the 2 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

1. Install disc rotor on hub.
2. Install support on housing. (Scheme 9) Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-163893-S42052495442004071500000). 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.
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-163893-S42052495442004071500000).
7. Connect brake hose. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163893-S42052495442004071500000). Replace brake hose gaskets with NEW ones.
8. Bleed air from brake system. See «BLEEDING PROCEDURES»(ref-163893-S42870140352004071500000) 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 12)
5. Raise caliper body. NOTE: If brake pad is difficult to remove, see steps A - D under FRONT DISC BRAKE PADS.
6. Remove pad from support. (Scheme 13) 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.
7. Check pad thickness. See «DISC BRAKE SPECIFICATIONS»(ref-163893-S07595305762004071500000).

Scheme 12

Scheme 13

1. Apply a thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad clip.
2. Install pad on support. (Scheme 13)
3. Install caliper body on support. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163893-S42052495442004071500000).

Removal & Installation

1. Lift vehicle and remove wheels.
2. Remove 2 mounting bolts and remove disc brake assembly. (Scheme 14)
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 gets away enough from the disc rotor. see scheme 3 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 15)
6. To install, reverse removal order.
7. Adjust the parking brake. See «PARKING BRAKE»(ref-163893-S27584804952004071500000) under ADJUSTMENTS.

Scheme 14

Scheme 15

1. Lift-up vehicle and remove wheels.
2. Disconnect brake hose from caliper body assembly. (Scheme 16)
3. Remove bolt securing lock pin to the caliper body. (Scheme 12)
4. Raise caliper body and move it towards the vehicle center to separate it from support.
5. 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.
6. 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.
7. Check caliper body and piston for uneven wear, damage or rust.
8. Check rubber parts for deterioration.
9. Repair or replace faulty parts.

Scheme 16

1. Install disc rotor on hub.
2. Install support on back plate. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163893-S42052495442004071500000) . 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. See «TORQUE SPECIFICATIONS»(ref-163893-S42052495442004071500000) .
6. Connect brake hose. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-163893-S42052495442004071500000) . 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-163893-S42870140352004071500000) under BLEEDING BRAKE SYSTEM.

1. Lift-up vehicle.
2. Remove rear tire and wheel.
3. Remove console box. Remove shift knob (MT model) and front cover. Remove tray and console cover. Remove console box.
4. Loosen the parking cable adjusting nut and console bracket.
5. Remove the parking brake lever. (Scheme 17)
6. Unbend the parking brake lever pawls and remove cable. (Scheme 18)
7. To install, reverse removal order. Tighten parking brake lever to specification. See «TORQUE SPECIFICATIONS»(ref-163893-S42052495442004071500000).
8. Be sure to pass the cable through the guide inside tunnel. Be sure to adjust the lever stroke. See «LEVER ADJUSTMENT»(ref-163893-S01214762942004071500000) under PARKING BRAKE under ADJUSTMENTS.
9. 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-163893-S27584804952004071500000) under ADJUSTMENTS.

Scheme 17

Scheme 18

1. Lift-up vehicle.
2. Remove rear tires and wheels.
3. Remove rear seat cushion.
4. Remove console box. Remove shift knob (MT model) and front cover. Remove tray and console cover. Remove console box.
5. Loosen parking cable adjusting nut and console bracket.
6. Remove parking brake lever. (Scheme 17)
7. Unbend the parking brake lever pawls and remove cable. (Scheme 18)
8. Roll up floor mat and remove clamps. (Scheme 19)
9. Remove equalizer cover.
10. Remove inner cable end from equalizer. (Scheme 20)
11. Pull out parking brake cable from rear brake. See «PARKING BRAKE ASSEMBLY»(ref-163893-S40851666732004071500000).
12. Pull out clamp from rear brake.
13. Remove bolt and bracket from trailing link bracket.
14. Remove bolt and clamp from rear floor. (Scheme 21)
15. Detach grommet from rear floor.
16. Remove cable assembly from cabin by forcibly pulling it backward.
17. Detach parking brake cable from cable guide at rear trailer link.
18. Inspect parking brake cable and replace it if 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.
19. Install NEW parking brake assembly in reverse order of removal.
20. Be sure to pass cable through the cable guide inside tunnel. Adjust the lever stroke. See «LEVER ADJUSTMENT»(ref-163893-S01214762942004071500000) under PARKING BRAKE under ADJUSTMENTS.

Scheme 19

Scheme 20

Scheme 21

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 14)
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. see scheme 3 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 15)
9. Remove the shoe 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 rear shoe hold down spring and pin with pliers. (Scheme 22)
14. Remove brake shoe.
15. Remove parking cable from parking lever. (Scheme 23)
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. The disc inside diameter standard measurement is 6.69" (170 mm) and the service limit is 6.73" (171 mm). If the disc is scored or worn, replace the brake disc.
18. Measure the lining thickness. The lining thickness standard measurement is 0.126" (3.2 mm) and the service limit is 0.059" (1.5 mm). If it exceeds the limit, replace the shoe assembly. CAUTION: Replace the brake shoes on the right and left brake assembly at the same time.

Scheme 22

Scheme 23

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 24) Ensure that the shoe return spring is installed as shown. (Scheme 25)
3. Adjust the parking brake. See «PARKING BRAKE»(ref-163893-S27584804952004071500000) 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 24

Scheme 25

1. Thoroughly drain brake fluid from reservoir tank.
2. Disconnect fluid level indicator harness connector.
3. Remove brake pipes from master cylinder.
4. Remove master cylinder mounting nuts, and take master cylinder out from brake booster.
5. 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.
6. To install, reverse removal procedures. Tighten the master cylinder mounting nut and the piping flare nut to specifications. See «TORQUE SPECIFICATIONS»(ref-163893-S42052495442004071500000) . NOTE: Be sure to use recommended brake fluid. See «BRAKE FLUID»(ref-163893-S34553124582004071500000) under BLEEDING BRAKE SYSTEM.

1. Pull up parking brake lever, and block tires.
2. Disconnect ground cable from battery.
3. 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.
4. Remove the following parts from the pedal bracket: Remove snap pin and clevis pin. Remove 4 brake booster installing nuts. 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 27) See «BRAKE BOOSTER SPECIFICATIONS»(ref-163893-S21965561862004071500000) table.
5. Remove the brake booster while shunning brake pipes.

Scheme 26

Scheme 27

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 28)
3. Connect the vacuum hose to the brake booster. (Scheme 29)
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 30) If it is not to specified length, adjust it by adjusting the brake booster operating rod. See «BRAKE BOOSTER SPECIFICATIONS»(ref-163893-S21965561862004071500000) table.
8. Measure the clearance between threaded end of stoplight switch and stopper. (Scheme 31) If stoplight switch clearance is not to specification, adjust it by adjusting the position of the stoplight switch. See «BRAKE BOOSTER SPECIFICATIONS»(ref-163893-S21965561862004071500000) table. CAUTION: Do not rotate the stoplight 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-163893-S42052495442004071500000).
11. Conduct road tests to ensure brakes do not drag.

Scheme 28

Scheme 29

Scheme 30

Scheme 31