Subaru Outback manuals

Subaru Outback: Rear Brake Pad

A: REMOVAL

1) Lift up the vehicle, and then remove the rear wheels.

2) Remove the rear brake pad.

  1. Remove the bolts and remove the brake hose bracket.
  2. Remove the caliper bolt, and raise and hold the caliper body.

NOTE: Do not disconnect the brake hose from the caliper body.

Subaru Outback. Brake

  1. Remove the brake pad from support.

Subaru Outback. Brake

B: INSTALLATION

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

1) Before installation, check the brake pad. <Ref. to BR-31, INSPECTION, Rear Brake Pad.>

2) Apply a thin coat of Molykote M7439 (Part No. 003602001) or grease contained in the pad kit to the pad clip.

Subaru Outback. Brake

3) Apply a thin coat of Molykote AS880N (Part No. K0777YA010) or grease contained in the pad kit between the outer pad and shim.

Subaru Outback. Brake

4) 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.

Subaru Outback. Brake

5) Install the brake pad to the support.

6) Install the caliper body to the support.

Tightening torque: Caliper bolt: 27 N*m (2.75 kgf-m, 19.9 ft-lb)

7) Install the brake hose bracket.

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

8) Install the rear wheels.

C: INSPECTION

1) Check the pad thickness (A).

NOTE:

Subaru Outback. Brake

Subaru Outback. Brake

2) If the wear limit is exceeded in the inspection, replace the brake pad.

Rear Disc Rotor

A: REMOVAL

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.

  1. Remove the bolt from the brake hose bracket.
  2. Remove the mounting bolt, and remove the caliper body assembly.

Subaru Outback. Brake

  1. Prepare wiring harnesses etc. to be discarded, and suspend the caliper body assembly from the shock absorber with the harnesses.

Subaru Outback. Brake

4) Remove the rear disc rotor.

NOTE: If it is difficult to remove the disc rotor, perform the following two methods in order.

1. Insert the flat tip screwdriver into the brake adjustment hole (A), and rotate the adjusting screw until the brake shoe moves far enough to remove the disc rotor.

Subaru Outback. Brake

  1. Adjusting screw
  2. Flat tip screwdriver
  3. Disc rotor

2. 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.

Subaru Outback. Brake

B: INSTALLATION

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

1) Before installation, check the rear disc rotor. <Ref. to BR-34, INSPECTION, Rear Disc Rotor.>

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

3) Adjust the parking brake. <Ref. to PB-15, ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).>

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)

C: INSPECTION

1. DISC ROTOR RUNOUT CHECK

1) Check the rear hub unit bearing for free play and runout before the inspection of disc rotor runout limit.

<Ref. to DS-47, INSPECTION, 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, and check the disc rotor runout while rotating the disc rotor.

Disc rotor runout limit: 0.05 mm (0.0020 in)

Subaru Outback. Brake

4) If the runout limit is exceeded in the inspection, replace the disc rotor.

2. DISC ROTOR THICKNESS CHECK

1) Set a micrometer 10 mm (0.39 in) inward from the disc rotor outer perimeter, and then measure the disc rotor thickness (A).

Subaru Outback. Brake

Subaru Outback. Brake

2) If the wear limit is exceeded in the inspection, replace the disc rotor.

Rear Disc Brake Assembly

A: REMOVAL

CAUTION: Do not allow brake fluid to come in contact with the painted surface of the vehicle body. If it does, wash off with water and wipe away completely.

1) Lift up the vehicle, and then remove the rear wheels.

2) Remove the caliper body from support.

  1. Remove the brake hose bracket and union bolt.

Subaru Outback. Brake

  1. Remove the caliper bolt, and remove the caliper body.

Subaru Outback. Brake

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.

  1. Remove the brake pad from support.
  2. Remove the mounting bolts, and then remove the support from the rear axle housing.

B: INSTALLATION

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

1) Before installation, check each part. <Ref. to BR-40, INSPECTION, Rear Disc Brake Assembly.>

2) Apply a thin coat of Molykote M7439 (Part No. 003602001) or the grease included with pad kit to the support.

Subaru Outback. Brake

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.

Subaru Outback. Brake

5) Apply a thin coat of Molykote AS880N (Part No. K0777YA010) or grease contained in the pad kit between the outer pad and shim.

Subaru Outback. Brake

6) 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.

Subaru Outback. Brake

7) Install the brake pad to the support.

8) Install the caliper body to the support.

Tightening torque: Caliper bolt: 27 N*m (2.75 kgf-m, 19.9 ft-lb)

9) Install the brake hose bracket.

Tightening torque: Brake hose bracket: 33 N*m (3.4 kgf-m, 14.3 ft-lb)

10) 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)

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

12) Install the rear wheels.

C: DISASSEMBLY

CAUTION: Be careful not to allow foreign matter to enter the brake hose connector.

1) Remove mud and foreign matter from the caliper body.

2) Remove the piston boot from caliper body cylinder.

Subaru Outback. Brake

3) Remove the piston.

  1. Place a wooden block in the caliper body as shown in the figure to prevent the piston from jumping out and being damaged.
  2. Using an air gun, gradually apply compressed air via the brake hose installation hole to push the piston out.

Subaru Outback. Brake

  1. Place a wooden block of 30 mm (1.18 in) width.

4) Remove the piston seal from caliper body cylinder.

CAUTION: Do not damage the cylinder and piston seal groove.

Subaru Outback. Brake

5) Remove the guide pin, lock pin, bushing pin, and pin boot from the support.

Subaru Outback. Brake

  1. Guide pin (black)
  2. Lock pin (silver)
  3. Bushing
  4. Pin boot

D: ASSEMBLY

1) Before installation, check each part. <Ref. to BR-40, INSPECTION, Rear Disc Brake Assembly.>

2) Clean the inside of the caliper body cylinder using brake fluid.

3) Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body cylinder groove.

4) Apply a coat of brake fluid to the inner surface of caliper body cylinder and the entire outer surface of the piston.

5) Apply grease contained in the piston seal kit to the piston boot, and install it to the groove at the end of the cylinder.

6) Insert the piston into caliper body cylinder.

CAUTION: Do not force the piston into caliper body cylinder.

7) Position the piston boot in the grooves on caliper body cylinder and piston.

Subaru Outback. Brake

  1. Piston
  2. Piston boot
  3. Caliper body
  4. Piston seal

8) Apply grease contained in the piston seal kit to the lock pin, guide pin outer surface, support cylinder inner surface, and pin boot grooves.

9) Install the pin boot to the lock pin and guide pin, and insert it into the support cylinder.

CAUTION: Insert the lock pin and guide pin into specified position, and make sure that they slide and seat properly.

Subaru Outback. Brake

  1. Pin boot
  2. Lock pin or guide pin
  3. Grease applied area

E: INSPECTION

1) Check the caliper body cylinder and piston for uneven wear, damage or rust.

2) Check the rubber parts for damage or deterioration.

3) If faulty is found in the inspection, replace the relevant part.

Master Cylinder

A: REMOVAL

CAUTION: Do not allow brake fluid to come in contact with the painted surface of the vehicle body. If it does, wash off with water and wipe away completely.

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.

Subaru Outback. Brake

  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.

Subaru Outback. Brake

B: INSTALLATION

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.

Subaru Outback. Brake

  1. Primary piston
  2. Seal sub ASSY
  3. Install the seal sub assembly to this surface.

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

CAUTION:

Subaru Outback. Brake

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. <Ref. to BR-54, PROCEDURE, Air Bleeding.>

C: REPLACEMENT

CAUTION: Since the master cylinder assembly cannot be disassembled, disassembly and cleaning are prohibited.

When replacing, replace the master cylinder assembly.

READ NEXT:

 Brake Booster

A: REMOVAL CAUTION: Do not allow brake fluid to come in contact with the painted surface of the vehicle body. If it does, wash off with water and wipe away completely. 1) Disconnect the ground cable

 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.

 Stop Light Switch

A: REMOVAL 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 li

SEE MORE:

 How to use as crossbars

CAUTION ● Do not raise the bar higher than necessary. The base of the bar may be damaged. ● Be careful not to contact the bars while sliding them. Otherwise, the bars may be scratched or the latch portions may be damaged. ● Do not slide the bar more than necessary when sliding

 Maximum load limits

WARNING Never exceed the maximum load limits explained in the following. Exceeding the maximum load limits could cause personal injury and/or vehicle damage. CAUTION ● Adequate size trailer brakes are required when the trailer and its cargo exceed 1,000 lbs (453 kg) total weight. χ

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