Subaru Outback manuals

Subaru Outback: Brake Hose

A: REMOVAL

1. FRONT BRAKE HOSE

1) Separate the brake pipe (b) from brake hose (a) using a flare nut wrench.

2) Remove the clamp, strut mounting bolt and union bolt, and remove the front brake hose.

Subaru Outback. Brake

2. REAR BRAKE HOSE

1) Remove the brake hose bracket bolt and union bolt.

Subaru Outback. Brake

2) Separate the brake pipe (a) using a flare nut wrench.

3) Remove the brake hose clamp (b), and remove the rear brake hose (c).

Subaru Outback. Brake

B: INSTALLATION

1. FRONT BRAKE HOSE

1) Secure the brake hose to strut mount.

Tightening torque: Brake hose: 33 N*m (3.36 kgf-m, 24.3 ft-lb)

2) Connect the brake hose to the front caliper body using a new gasket.

Tightening torque: Union bolt: 18 N*m (1.84 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 (1.53 kgf-m, 11.1 ft-lb)

7) Bleed air from the brake system. <Ref. to BR-54, PROCEDURE, Air Bleeding.>

2. REAR BRAKE HOSE

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.

Tightening torque: Brake hose bracket: 33 N*m (3.36 kgf-m, 24.3 ft-lb)

3) Install the brake hose to rear caliper body using a new gasket.

Tightening torque: Union bolt: 18 N*m (1.84 kgf-m, 13.3 ft-lb)

4) Tighten the flare nut to the specified torque.

Tightening torque: Brake pipe flare nut: 15 N*m (1.53 kgf-m, 11.1 ft-lb)

5) Bleed air from the brake system. <Ref. to BR-54, PROCEDURE, Air Bleeding.>

C: INSPECTION

Check the hose for crack and damage, and also check the connection for fluid leakage. If any faulty is found, repair or replace the relevant part.

Brake Pipe

A: REMOVAL

CAUTION:

NOTE: The airbag system wiring harness is routed near the center brake pipe.

B: INSTALLATION

CAUTION:

NOTE: The airbag system wiring harness is routed near the center brake pipe.

Tightening torque:
Front brake pipes & hoses: <Ref. to BR-7, FRONT BRAKE PIPES AND HOSES, COMPONENT, General Description.>
Center & rear brake pipes and hoses: <Ref. to BR-8, CENTER AND REAR BRAKE PIPES AND HOSES, COMPONENT, General Description.>

C: INSPECTION

Check the pipe for crack and damage, and also check the connection for fluid leakage. If any faulty is found, repair or replace the relevant part.

NOTE: Use a mirror when inspecting back sides and other locations which are hard to see.

Brake Pedal

A: REMOVAL

1. AT MODELS AND CVT MODELS

1) Disconnect the ground cable from battery.

2) Remove the instrument panel lower cover.

  1. Remove the clips, and remove the instrument panel side cover LH.

Subaru Outback. Brake

  1. Remove the clips and data link connector, and remove the instrument panel lower cover under.

Subaru Outback. Brake

  1. Remove the bolts, and remove the knee guard panel.

Subaru Outback. Brake

  1. Remove the screws and clips and release the claws, and remove the instrument panel lower cover while disconnecting the harness connectors.

Subaru Outback. Brake

3) Remove the brake pedal assembly.

  1. Disconnect the stop light switch connector.
  2. Remove the snap pin (a) and clevis pin (b), and remove the operating rod from the brake pedal.

NOTE:

Subaru Outback. Brake

  1. Remove the bolt and nut, and then detach the brake pedal assembly.

Subaru Outback. Brake

2. MT MODEL

NOTE: Brake pedal is integrated with the clutch pedal.

For removal procedures of the brake pedal, refer to Clutch section. <Ref. to CL-26, REMOVAL, Clutch Pedal.>

B: INSTALLATION

1) Install each part in the reverse order of removal.

CAUTION:

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. <Ref. to BR-63, INSPECTION, Brake Pedal.>

C: INSPECTION

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

Subaru Outback. Brake

  1. Brake pedal

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).]

Subaru Outback. Brake

  1. Stop light switch
  2. Mat
  3. Toe board
  4. Brake booster operating rod

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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