Brake System: Other Subaru Outback BR

CAUTION

1. Wear appropriate work clothing, including a cap, 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 in 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 56

Scheme 57

1. Lift up the vehicle, and remove the front wheels.
2. Remove the caliper bolt.
3. Raise the caliper body and support it. NOTE: Do not disconnect the brake hose from the caliper body.
4. Remove the pad.

Scheme 58

Scheme 59

1. Apply a thin coat of Molykote M7439 (Part No. K0770YA000) or grease contained in the pad kit to the pad clip.
2. Apply a thin coat of Molykote AS880N (Part No. K0777YA010) or grease contained in the pad kit to both surfaces of the pad and inner shim.
3. Install the pad to support.
4. Install the caliper body to the support. Tightening torque: 27 N.m (2.8 kgf-m, 19.9 ft-lb)

Scheme 60

Scheme 61

1. Apply a thin coat of Molykote M7439 (Part No. K0770YA000) or grease contained in the pad kit to the pad clip.
2. Apply a thin coat of Molykote AS880N (Part No. K0777YA010) or grease contained in the pad kit to both surfaces of the pad and inner shim.
3. Install the pad to support. NOTE: Install the pad indicator in proper direction. 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 figure. Correctly install the pad return spring to the supporting surface of the pad clip as shown in the figure. If the pad return spring is deformed or damaged, replace the brake pad.
4. Install the caliper body to the support. Tightening torque: 27 N.m (2.8 kgf-m, 19.9 It-lb)

16-INCH TYPE

Check the pad thickness A.

Scheme 62

PAD THICKNESS SPECIFICATION

Note. Always replace the pads of both wheels and both sides as a set. Replace pad clips if they are twisted or worn. Replace the pad if there is oil or grease on it.

17-INCH TYPE

Check the pad thickness A.

PAD THICKNESS SPECIFICATION

Note. Always replace the pads of both wheels and both sides as a set. Replace the pad if there is oil or grease on it.

Scheme 63

Scheme 64

1. Lift up the vehicle, and remove the front wheels.
2. Remove the caliper body and the support from housing, and suspend them from the strut using a wire.
3. Remove the disc rotor. NOTE: If it is difficult to remove the disc rotor from the hub, drive an 8 mm bolt into the threaded section (B) of the rotor, then remove the rotor.
4. Remove mud and foreign matter from the caliper body assembly and the support.

PROCEDURE

MASTER CYLINDER

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

Scheme 65

Scheme 66

1. Fill the reservoir tank of the master cylinder with brake fluid. NOTE: While bleeding air, keep the reservoir tank filled with brake fluid to prevent entry of air.
2. Disconnect the brake line at primary and secondary sides.
3. Wrap the master cylinder 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. Install the brake pipe to the master cylinder. Tightening torque: 19 N.m (1.9 kgf-m, 14 ft-lb)
9. Bleed air from the brake line. Ref. to «BRAKE LINE»(ref-371905-S31304185272010091900000) , PROCEDURE, Air Bleeding.

Scheme 67

Scheme 68

1. When the master cylinder is replaced or the reservoir tank is empty, bleed the master cylinder before bleeding the brake line. Ref. to «MASTER CYLINDER»(ref-371905-S27256570352010091900000) , PROCEDURE, Air Bleeding.
2. Fill the reservoir tank of the master cylinder 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 air bleeder and the other end to the brake fluid container.
4. Depress the brake pedal several times, and keep it pressed.
5. Loosen the air bleeder screw to drain brake fluid. Tighten the air bleeder 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 the operation in the order starting from the farthest wheel cylinder from the master cylinder.
8. Securely tighten the air bleeder screws. Tightening torque: 8 N.m (0.8 kgf-m, 5.9 ft-lb)
9. Check that there are no brake fluid leaks in the entire system.
10. Check the pedal stroke. Run the engine at idle after warming up the engine, and depress the brake pedal with a force of 500 N (51 kgf, 112 lbf). Measure the distance between the brake pedal and steering wheel. Release the pedal, and measure the distance between pedal and steering wheel again. Specification of pedal stroke: When depressing the pedal with a force of 500 N (51 kgf, 112 lbf). 100 mm (3.94 in) or less
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-371945-S42644308032010091900000) .
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. Test run the vehicle and ensure that the brakes operate normally.

Scheme 69

1. Separate the brake pipe from brake hose using a flare nut wrench.
2. Remove the clamp, the strut mount bolts, and union bolt.

Scheme 70

1. Remove the union bolt and brake hose bracket.
2. Separate the brake pipe from brake hose using a flare nut wrench.
3. Remove the clamp, and then remove the brake hose.

FRONT BRAKE HOSE

1. Secure the brake hose to strut mount. Tightening torque: 33 N.m (3.4 kgf-m, 24.3 ft-lb)
2. Install the brake hose to the caliper using a new gasket. Tightening torque: Union bolt 18 N.m (1.8 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. Tighten the flare nut to the specified torque. Tightening torque: Brake pipe flare nut 15 N.m (1.5 kgf-m, 11.1 ft-lb)
7. Bleed air from the brake system.

Scheme 71

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.
3. Install the brake hose to rear brake caliper using a new gasket. Tightening torque: Union bolt 18 N.m (1.8 kgf-m, 13.3 ft-lb) Frame hose bracket 33 N.m (3.4 kgf-m, 24.3 ft-lb)
4. Tighten the flare nut to the specified torque. Tightening torque: Brake pipe flare nut 15 N.m (1.5 kgf-m, 11.1 ft-lb)
5. Bleed air from the brake system.

MT MODEL

Refer to "CLUTCH PEDAL". Ref. to REMOVAL , Clutch Pedal.

Scheme 72

1. Install the bolt and nut which secures the brake pedal bracket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
2. Install the clevis pin and snap pin which secure the operating rod and brake pedal. NOTE: Replace the clevis pin with a new part. Apply NIGTIGHT LYW NO. 2 grease to the clevis pin.
3. Connect the stop light switch connector.
4. Check the brake light illumination condition.
5. Check the brake pedal after installation. Ref. to «INSPECTION»(ref-371905-S02071491652010091900000) , Brake Pedal.

Refer to "CLUTCH PEDAL". Ref. to INSTALLATION , Clutch Pedal.

Scheme 73

Scheme 74

1. Move the brake pedal pads in a horizontal direction with a force of approx. 10 N (1 kgf, 2 lbf), and check that the pedal deflection is in the range of specifications. CAUTION: If excessive deflection is noted, replace with a new bushing. Deflection of brake pedal: Limit 5.0 mm (0.197 in) or less
2. Check the position of the pedal pad. Pedal height L: 140 - 150 mm (5.51 - 5.91 in) Brake pedal free play A: 2 - 5 mm (0.079 - 0.197 in) [When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lbf).]
3. If it is not within the specification, loosen the lock nuts of brake booster operating rod, and rotate the rod to adjust the pedal height L within the specification.
4. Tighten the lock nut. Tightening torque: 22 N.m (2.2 kgf-m, 16.2 ft-lb)

Scheme 75

1. Disconnect the ground cable from battery.
2. Disconnect the stop light switch connector.
3. Loosen the nuts, unscrew the stop light switch, and remove stop light switch.

Scheme 76

1. Install the stop light switch onto the bracket with screws and position it with the nut.
2. Adjust the stop light switch position, and then tighten the nut. Ref. to «ADJUSTMENT»(ref-371905-S20841271292010091900000) , Stop Light Switch. Tightening torque: 8 N.m (0.8 kgf-m, 5.9 ft-lb)

Scheme 77

Scheme 78

1. If the stop light switch does not operate properly (or if it is not secured at the specified position), replace with a new part. Specified position L: 2.8 mm +1.5 mm -0 mm (0.11 in +0.06 in -0 in )
2. Measure the clearance between the threaded end of the stop light switch and the stopper. CAUTION: Be careful not to rotate the stop light switch. Stop light switch clearance A: 0.8 mm (0.031 in)
3. If it is not within the specification, adjust it by adjusting the position of the stop light switch. CAUTION: Be careful not to rotate the stop light switch.

Scheme 79

1. Measure the resistance of stop light switch. RESISTANCE SPECIFICATION Switch Pedal Terminal No. Standard Stop light Released 2 and 3 1 Mohms or more Depressed Less than 1 ohms
2. If the stop light switch does not operate properly, replace with a new part.