Subaru Outback (BR): 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.

2. REAR BRAKE HOSE

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

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).

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:

• Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits.
• Be careful not to damage the airbag system wiring harness when servicing the center brake pipe.
• When removing the brake pipe, do not bend.

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

B: INSTALLATION

CAUTION:

• Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits.
• Be careful not to damage the airbag system wiring harness when servicing the center brake pipe.
• When installing the brake pipe, do not bend.
• After installing the brake pipe and hose, perform air bleed.
• After installing the brake hoses, make sure that they do not contact the tires or suspension assembly, etc.

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.

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

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

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

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:

• Use special care when handling the operating rod. If excessive force is applied to the operating rod, the angle may change by +-3º, and it may result in damage to power piston cylinder.
• Do not change the push rod length.

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

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:

• 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. <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

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).]

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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