Brake System: Removal & Installation Subaru Outback BR

INSTALLATION

1. Install the disc rotor.
2. Install the caliper body and the support to housing. Tightening torque: 120 N.m (12.2 kgf-m, 88.5 ft-lb)
3. Install the front wheels.

Scheme 26

1. Check the front wheel bearing play and axle hub runout before the inspection of disc rotor runout limit. Ref. to «INSPECTION»(ref-371909-S12563561642010091900000) , 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 service limit, grind the disc rotor. After grinding, check the thickness of the disc rotor by following 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 of disc rotor exceeds the service limit, replace with a new disc rotor. DISC ROTOR OUTER DIAMETER SPECIFICATION Standard Limit Disc rotor outer diameter Disc rotor thickness A mm (in) 16" 24 (0.94) 22 (0.87) 294 (11.57) 17" 30 (1.18) 28 (1.10) 316 (12.44)

REMOVAL

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1. Lift up the vehicle, and remove the front wheels.
2. Remove the union bolt, and disconnect the brake hose from the caliper body assembly.
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 support from housing. NOTE: Remove the support only when replacing the rotor or support. It is not necessary to remove it when servicing the caliper body assembly.
6. Remove mud and foreign matter from the caliper body assembly and the support.

Scheme 30

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: 120 N.m (12.2 kgf-m, 88.5 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 and inner shim.
5. Install the pad to support.
6. Install the caliper body to the support. Tightening torque: 27 N.m (2.8 kgf-m, 19.9 ft-lb)
7. Connect the brake hose using a new brake hose gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
8. Bleed air from the brake system.

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1. Apply a thin coat of Molykote M7439 (Part No. K0770YA000) to the support.
2. Install the support to the housing. Tightening torque: 120 N.m (12.2 kgf-m, 88.5 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 and inner shim.
5. 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.
6. Install the caliper body to the support.
7. Connect the brake hose using a new brake hose gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
8. Bleed air from the brake system.

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1. Remove mud and foreign matter from the caliper body assembly 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 figure 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 from caliper body cylinder. CAUTION: Do not damage the cylinder and piston seal groove.
6. Remove the guide pin and boot from caliper body.

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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 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. Position the boot in the grooves on cylinder and piston.
7. Apply 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 in the reverse order of removal. Tightening torque: Ref. to «COMPONENT»(ref-371905-S29554048842010091900000) , General Description.
2. Adjust the parking brake. Ref. to «ADJUSTMENT»(ref-371906-S06352688602010091900000) , Parking Brake Assembly (Rear Disc Brake).

Scheme 39

1. Check the rear wheel bearing play and axle hub runout before inspecting the disc rotor runout limit. Ref. to «INSPECTION»(ref-371909-S01444470202010091900000) , 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 service limit, grind the disc rotor. After grinding, check the thickness of the disc rotor by following 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 of disc rotor exceeds the service limit, replace with a new disc rotor. DISC ROTOR THICKNESS SPECIFICATION Standard Limit Disc outer dia. Disc rotor thickness A mm (in) Solid disc 10 (0.39) 8.5 (0.335) 286 (11.26) Ventilated disc 18 (0.71) 16 (0.63) 290 (11.42)

Scheme 40

1. Lift up the vehicle, and then remove the rear wheels.
2. Disconnect the brake hoses.
3. Remove the caliper mounting bolt.
4. Raise the caliper body, and then move it toward vehicle center to separate it from the support.
5. Remove the support from housing. NOTE: Remove the support only when replacing the rotor or support. It is not necessary to remove it when servicing the caliper body assembly.
6. Remove mud and foreign matter from the caliper body assembly 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 (6.7 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 between the outer 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 inner pad inner shim.
6. Install the pad to support.
7. Install the caliper body to the support. Tightening torque: 27 N.m (2.8 kgf-m, 19.9 ft-lb)
8. Install the brake hose bracket. Tightening torque: 33 N.m (3.4 kgf-m, 14.3 ft-lb)
9. Connect the brake hose using a new brake hose gasket. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
10. Bleed air from the brake system.

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1. Remove the piston boot.
2. Place a wooden block in the caliper body as shown in the figure 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 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. Position the boot in the grooves on piston and cylinder.
7. Apply grease contained in the piston seal kit to the cylinder inner surface, pin, bushing outer surface, and boot grooves.
8. Insert the pin boot to the support.
9. Install the pin boot to the support, and then insert the pin sleeve into the specified position. CAUTION: Insert the pin into specified position, and make sure that they slide and seat properly.

Scheme 46

1. Drain brake fluid from 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 remove the master cylinder slowly from the brake booster. CAUTION: In order to prevent the contact of the bracket and check valve, be sure to loosen the master cylinder mounting nut while holding the bracket with hand. Otherwise it may deform the bracket.

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1. Replace the seal sub assembly for the master cylinder with a new part. CAUTION: Be careful not to install the seal sub assembly in the wrong location.
2. Install in the reverse order of removal. CAUTION: Install the bracket at the position with sufficient clearance that it does not contact with the check valve. Be sure to loosen the master cylinder mounting nut while holding the bracket with hand. Otherwise the bracket may deform. Tightening torque: Master cylinder mounting nut 13 N.m (1.3 kgf-m, 9.6 ft-lb) Piping flare nut 19 N.m (1.9 kgf-m, 14 ft-lb)
3. Bleed air from brake system. Ref. to «PROCEDURE»(ref-371905-S05679069842010091900000) , Air Bleeding. CAUTION: Be sure to use recommended brake fluid.

REPLACEMENT

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1. Remove or disconnect the following parts in the engine compartment. Disconnect the connector of brake fluid level gauge. Remove the brake pipe from the master cylinder. Remove the master cylinder installation nut. CAUTION: In order to prevent the contact of the bracket and check valve, be sure to loosen the master cylinder mounting nut while holding the bracket with hand. Otherwise it may deform the bracket. Disconnect the vacuum hose from brake booster.
2. Remove the following parts from the pedal bracket. Snap pin and clevis pin Four brake booster installation nuts
3. Remove the brake booster while avoiding the brake pipe. NOTE: Make sure that the booster shell and vacuum pipe are not subject to strong impacts. Be careful not to drop the brake booster. If the booster is dropped, replace it. Use special care when handling the operating rod. If excessive force is applied to the operating rod, the angle may change by ±3°, and it may result in damage to power piston cylinder. Be careful when placing the brake booster on floor. Do not change the push rod length. CAUTION: Do not disassemble the brake booster. If external force is applied from above when brake booster is placed in this position, the resin portion as indicated by "P" may become damaged.

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1. Check and adjust the operating rod of the brake booster. Specification L: 136.5 mm (5.37 in) If it is out of specification, adjust it with the brake booster operating rod.
2. Mount the brake booster in position.
3. Tighten the brake booster mounting nuts. Tightening torque: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
4. 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.
5. Connect the vacuum hose to the brake booster.
6. After replacing the seal sub assembly with a new part, install the master cylinder to brake booster. Tightening torque: 13 N.m (1.3 kgf-m, 9.6 ft-lb) CAUTION: Install the bracket at the position with sufficient clearance that it does not contact with the check valve. Be sure to loosen the master cylinder mounting nut while holding the bracket with hand. Otherwise the bracket may deform.
7. Connect the brake pipes to the master cylinder. Tightening torque: 19 N.m (1.9 kgf-m, 14 ft-lb)
8. Connect the connector of the brake fluid level gauge.
9. Apply grease to the operating rod connecting pin to prevent it from wear.
10. Bleed air from brake system. Tightening torque (air bleeder screw): 8 N.m (0.8 kgf-m, 5.9 ft-lb)
11. Perform the road test to make sure the brakes do not drag.

Note. During the operation, keep the reservoir tank filled with brake fluid to eliminate entry of air. Operate the brake pedal slowly. For convenience and safety, two people should do the work. The required amount of brake fluid is approximately 500 m l (16.9 US fl oz, 17.6 lmp 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 the recommended brake fluid. Recommended brake fluid: Refer to the specification of "General Description". Ref. to «SPECIFICATION»(ref-371905-S32114885982010091900000) , General Description.

Perform the same procedure as for bleeding the brake line, until new brake fluid comes out from vinyl tube. Ref. to PROCEDURE , 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" of "General Description". Ref. to FRONT BRAKE PIPES AND HOSES , COMPONENT, General Description. Ref. to CENTER AND REAR BRAKE PIPES AND HOSES , COMPONENT, General Description.