Brake System: Removal & Installation Subaru Outback BR рестайлинг

INSTALLATION

Note. Before installation, remove mud and foreign matter from the caliper body and support.

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1. Before installation, check the brake pad. Refer to «INSPECTION»(ref-565173-S12532159422013071000000) .
2. Apply a thin coat of grease contained in the pad kit to the pad clip.
3. 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.
4. Install the brake pad to the support. 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. NOTE: Install the brake pad indicator in proper direction.
5. Install the caliper body to the support.
6. Install the front wheels. Tightening torque: Caliper bolt: 27 N.m (2.75 kgf-m, 19.9 ft-lb)

Scheme 31

1. Check the pad thickness (A). 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. Standard Wear limit Pad thickness (A) 11 mm (0.43 in) 1.5 mm (0.059 in)
2. If the wear limit is exceeded in the inspection, replace the brake pad.

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1. Lift up the vehicle, and then remove the front wheels.
2. Remove the caliper body assembly from the front axle housing. Remove the bolt from the brake hose bracket. Remove the mounting bolt, and remove the caliper body assembly. Prepare wiring harnesses etc. to be discarded, and suspend the caliper body assembly from the shock absorber with the harnesses.
3. Remove the front disc rotor. NOTE: When the disc rotor is difficult to be removed from the front hub unit bearing, screw in 8 mm (0.31 in) bolt to the threaded part of the disc rotor (A), and remove the disc rotor.

Note. Before installation, remove mud and foreign matter from the caliper body assembly.

1. Before installation, check the front disc rotor. Refer to «INSPECTION»(ref-565173-S12485441962013071000000) .
2. Install each part in the reverse order of removal. Tightening torque: Brake hose bracket: 33 N.m (3.36 kgf-m, 24.3 ft-lb) Mounting bolt: 120 N.m (12.24 kgf-m, 88.5 ft-lb)

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1. Check the front hub unit bearing for free play and runout before the inspection of disc rotor runout limit. Refer to «INSPECTION»(ref-565177-S33658158122013071000000) .
2. Tighten the wheel nuts to secure disc rotor.
3. Set a dial gauge 10 mm (0.39 in) inward from the disc rotor outer circumference, and check the disc rotor runout while rotating the disc rotor. Disc rotor runout limit: 0.05 mm (0.0020 in)
4. If the runout limit is exceeded in the inspection, replace the disc rotor.

Scheme 36

1. Set a micrometer 10 mm (0.39 in) inward from the disc rotor outer perimeter, and then measure the disc rotor thickness (A). Size Standard Wear limit Disc rotor outer diameter Disc rotor thickness (A) 16-inch 24 mm (0.94 in) 22 mm (0.87 in) 294 mm (11.57 in) 17-inch 30 mm (1.18 in) 28 mm (1.10 in) 316 mm (12.44 in)
2. If the wear limit is exceeded in the inspection, replace the disc rotor.

REMOVAL

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1. Lift up the vehicle, and then remove the front wheels.
2. Remove the caliper body. Remove the union bolt and caliper bolt, and remove the caliper body from the support.
3. Remove the support. NOTE: Remove the support only when replacing the disc rotor or support. It is not necessary to remove it when servicing the caliper body. Remove the brake pad from support. Remove the mounting bolts, and then remove the support from the front axle housing.

Note. Before installation, remove mud and foreign matter from the caliper body and support.

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1. Before installation, check each part. Refer to «INSPECTION»(ref-565173-S23190653102013071000000) .
2. Apply a thin coat of grease to the support. Grease: Grease contained in the pad kit or WAKO grease V160
3. Install the support to the front axle housing. Tightening torque: Mounting bolt: 120 N.m (12.24 kgf-m, 88.5 ft-lb)
4. Apply a thin coat of grease contained in the pad kit to the pad clip.
5. 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.
6. Install the brake pad to the support. 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. NOTE: Install the brake pad indicator in proper direction.
7. Install the caliper body to the support. Tightening torque: Caliper bolt: 27 N.m (2.75 kgf-m, 19.9 ft-lb)
8. Connect the brake hose using a new brake hose gasket. Tightening torque: Union bolt: 18 N.m (1.84 kgf-m, 13.3 ft-lb)
9. Bleed air from the brake system. Refer to «BRAKE LINE»(ref-565173-S17641256992013071000000) .
10. Install the front wheels.

Note. Before installation, remove mud and foreign matter from the caliper body and support.

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1. Before installation, check the brake pad. Refer to «INSPECTION»(ref-565173-S22716509412013071000000) .
2. Apply a thin coat of grease contained in the pad kit to the pad clip.
3. Apply a thin coat of grease to the inner shim (a) and the outer shim (b). Grease: Grease contained in the pad kit or WAKO grease V160
4. Install the brake pad to the support.
5. Install the caliper body to the support. Tightening torque: Caliper bolt: 27 N.m (2.75 kgf-m, 19.9 ft-lb)
6. Install the brake hose bracket. Tightening torque: Brake hose bracket: 33 N.m (3.36 kgf-m, 24.3 ft-lb)
7. Install the rear wheels.

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1. Check the pad thickness (A). 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. A wear indicator is installed on the inner disc brake pad. If the pad is worn to the limit, the end of wear indicator contacts disc rotor, and a squeaking sound is heard as the wheel rotates. If the sound is heard, replace the pad. Disc rotor type Standard Wear limit Pad thickness (A) Solid 9 mm (0.35 in) 1.5 mm (0.059 in) Ventilated 11 mm (0.43 in) 1.5 mm (0.059 in)
2. If the wear limit is exceeded in the inspection, replace the brake pad.

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1. Lift up the vehicle, and then remove the rear wheels.
2. Release the parking brake.
3. Remove the caliper body assembly from the rear axle housing. Remove the bolt from the brake hose bracket. Remove the mounting bolt, and remove the caliper body assembly. Prepare wiring harnesses etc. to be discarded, and suspend the caliper body assembly from the shock absorber with the harnesses.
4. Remove the rear disc rotor. NOTE: If it is difficult to remove the disc rotor, perform the following two methods in order. Remove the adjusting hole cover (A), insert the flat tip screwdriver, and rotate the adjusting screw until the brake shoe moves far enough to remove the disc rotor. When the disc rotor is difficult to be removed from the rear hub unit bearing, screw in 8 mm (0.31 in) bolt to the threaded part of the disc rotor (A), and remove the disc rotor.

Note. Before installation, remove mud and foreign matter from the caliper body assembly.

1. Before installation, check the rear disc rotor. Refer to «INSPECTION»(ref-565173-S01825984322013071000000) .
2. Install each part in the reverse order of removal.
3. Adjust the parking brake. Refer to «ADJUSTMENT»(ref-565174-S26209469252013071000000) . Tightening torque: Brake hose bracket: 33 N.m (3.36 kgf-m, 24.3 ft-lb) Mounting bolt: 66 N.m (6.73 kgf-m, 48.7 ft-lb)

Scheme 50

1. Check the rear hub unit bearing for free play and runout before the inspection of disc rotor runout limit. Refer to «INSPECTION»(ref-565177-S08605396612013071000000) .
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, and check the disc rotor runout while rotating the disc rotor. Disc rotor runout limit: 0.05 mm (0.0020 in)
4. If the runout limit is exceeded in the inspection, replace the disc rotor.

Scheme 51

1. Set a micrometer 10 mm (0.39 in) inward from the disc rotor outer perimeter, and then measure the disc rotor thickness (A). Disc rotor type Standard Wear limit Disc rotor outer diameter Disc rotor thickness (A) Solid disc 10 mm (0.39 in) 8.5 mm (0.33 in) 286 mm (11.26 in) Ventilated disc 18 mm (0.71 in) 16 mm (0.63 in) 290 mm (11.42 in)
2. If the wear limit is exceeded in the inspection, replace the disc rotor.

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1. Lift up the vehicle, and then remove the rear wheels.
2. Remove the caliper body from support. Remove the brake hose bracket and union bolt. Remove the caliper bolt, and remove the caliper body.
3. Remove the support. NOTE: Remove the support only when replacing the disc rotor or support. It is not necessary to remove it when servicing the caliper body. Remove the brake pad from support. Remove the mounting bolts, and then remove the support from the rear axle housing.

Note. Before installation, remove mud and foreign matter from the caliper body and support.

Scheme 54

1. Before installation, check each part. Refer to «INSPECTION»(ref-565173-S03118774172013071000000) .
2. Apply a thin coat of grease contained in the pad kit to the support.
3. Install the support to the rear axle housing. Tightening torque: Mounting bolt: 66 N.m (6.73 kgf-m, 48.7 ft-lb)
4. Apply a thin coat of Molykote M7439 (Part No. 003602001) or grease contained in the pad kit to the pad clip.
5. Apply a thin coat of grease to the inner shim (a) and the outer shim (b). Grease: Grease contained in the pad kit or WAKO grease V160
6. Install the brake pad to the support.
7. Install the caliper body to the support. Tightening torque: Caliper bolt: 27 N.m (2.75 kgf-m, 19.9 ft-lb)
8. Install the brake hose bracket. Tightening torque: Brake hose bracket: 33 N.m (3.4 kgf-m, 14.3 ft-lb)
9. Connect the brake hose using a new brake hose gasket. Tightening torque: Union bolt: 18 N.m (1.84 kgf-m, 13.3 ft-lb)
10. Bleed air from the brake system. Refer to «BRAKE LINE»(ref-565173-S17641256992013071000000) .
11. Install the rear wheels.

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1. Disconnect the ground cable from battery.
2. Drain brake fluid from the reservoir tank completely.
3. Remove the master cylinder assembly. 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. Disconnect the fluid level gauge connector (a).
2. Disconnect the brake pipe (b).
3. Remove the nut (c), and slowly remove the master cylinder from the brake booster.

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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 each part 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: 13 N.m (1.33 kgf-m, 9.6 ft-lb) Brake pipe flare nut: 19 N.m (1.94 kgf-m, 14.0 ft-lb)
3. Bleed air from the brake system. Refer to «PROCEDURE»(ref-565173-S07827577212013071000000) .

REPLACEMENT

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1. Disconnect the ground cable from battery.
2. Drain brake fluid from the reservoir tank completely.
3. Remove the master cylinder assembly. 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 fluid level gauge connector (a). Disconnect the brake pipe (b). Remove the nut (c), and slowly remove the master cylinder from the brake booster.
4. Remove the brake booster. CAUTION: Do not disassemble the brake booster. If external force (1) is applied from above when brake booster is placed in this position, the resin portion as indicated by "P" may become damaged. Remove the clamp and remove the vacuum hose. Remove the clips, and remove the instrument panel side cover LH. Remove the clips and data link connector, and remove the instrument panel lower cover under. Remove the screws and clips and release the claws, and remove the instrument panel lower cover while disconnecting the harness connectors. Remove the bolts, and remove the knee guard panel. Remove the snap pin (a) and clevis pin (b), and remove the operating rod from the brake pedal. NOTE: 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. Do not change the push rod length. Remove the nut and remove the brake booster. 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 brake booster is dropped accidentally, replace it. Be careful when placing the brake booster on floor.

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1. Check and adjust the operating rod of the brake booster. Measure the length between the brake booster mounting surface and clevis pin hole. If it is not within specification, loosen the lock nut, rotate the brake booster operating rod to adjust the rod length. Specification L: 136.5 mm (5.37 in)
2. Install each part in the reverse order of removal. CAUTION: Apply grease to the snap pin to prevent the operating rod from wear. Replace the clevis pin with new parts, and apply thin coat of NIGTIGHT LYW No. 2 grease to the clevis pin. When installing the master cylinder assembly, replace the seal sub assembly with a new part, and install it to the brake booster. 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: Brake booster: 18 N.m (1.84 kgf-m, 13.3 ft-lb) Master cylinder: 13 N.m (1.33 kgf-m, 9.6 ft-lb) Brake pipe flare nut: 19 N.m (1.94 kgf-m, 14.0 ft-lb) Operating lock nut: 22 N.m (2.24 kgf-m, 16.2 ft-lb)
3. Bleed air from the brake system. Refer to «PROCEDURE»(ref-565173-S07827577212013071000000) .
4. Perform a road test to make sure the brakes do not drag.

Note. During the operation, keep the reservoir tank filled with brake fluid to prevent entry of air. Operate the brake pedal slowly. For convenience and safety, perform the work with 2 people. The required amount of brake fluid is approximately 500 mL (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 recommended brake fluid. Recommended brake fluid: FMVSS No. 116, DOT3, or DOT4 Perform the same procedure as for bleeding the brake line, until new brake fluid comes out from vinyl tube. Refer to «PROCEDURE»(ref-565173-S07827577212013071000000)

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.

Tightening torque

Front brake pipes & hoses: Refer to FRONT BRAKE PIPES AND HOSES .

Center & rear brake pipes and hoses: Refer to CENTER AND REAR BRAKE PIPES AND HOSES .

1. Install each part in the reverse order of removal. CAUTION: Apply grease to the snap pin to prevent the operating rod from wear. Replace the clevis pin with new parts, and apply thin coat of NIGTIGHT LYW No. 2 grease to the clevis pin. Tightening torque: Brake pedal: 18 N.m (1.84 kgf-m, 13.3 ft-lb)
2. Check that the brake light operate properly.
3. Check the brake pedal after installation. Refer to «INSPECTION»(ref-565173-S37033514202013071000000) .

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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: Wear 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: 0.2 - 0.5 mm (0.008 - 0.02 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: Operating lock nut: 22 N.m (2.24 kgf-m, 16.2 ft-lb)

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1. Disconnect the ground cable from battery.
2. Remove the instrument panel lower cover. Remove the clips, and remove the instrument panel side cover LH. Remove the clips and data link connector, and remove the instrument panel lower cover under. Remove the bolts, and remove the knee guard panel. Remove the screws and clips and release the claws, and remove the instrument panel lower cover while disconnecting the harness connectors.
3. Remove the stop light switch. Disconnect the stop light switch connector (a). Remove the nut (b), and remove the stop light switch.

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. Refer to «ADJUSTMENT»(ref-565173-S17125948362013071000000) .
3. Install each part in the reverse order of removal. Tightening torque: Stop light switch: 8 N.m (0.82 kgf-m, 5.9 ft-lb)

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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. Adjust the position of the stop light switch if the inspection result is not within the standard value. Refer to «ADJUSTMENT»(ref-565173-S17125948362013071000000) .

Scheme 74

1. Disconnect the stop light switch connector.
2. Measure the resistance between stop light switch terminals. Preparation tool: Circuit tester Terminal No. Inspection conditions Standard 2 - 3 When brake pedal is depressed Less than 1 ohms When brake pedal is released 1 Mohms or more
3. Replace the stop light switch if the inspection result is not within the standard value.

Scheme 75

1. Loosen the lock nut, and adjust the stop light switch position until the clearance (A) between the threaded end of the stop light switch and stopper becomes 0.8 mm (0.031 in). Then, tighten the lock nut.
2. Tighten the lock nut.