SUBARU TRIBECA 2009 1.G Service Workshop Manual

BR-17
Front Disc Brake Assembly
BRAKE
C: DISASSEMBLY
1) Remove mud and foreign matter from the caliper
body assembly and 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 jump-
ing 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.
D: ASSEMBLY
1) Clean the inside of the caliper body using brake
fluid.
2) Apply a coat of brake fluid to piston seal and in-
stall piston seal in the groove on caliper body.
3) Apply a coat of brake fluid to the inner surface of
cylinder and the entire outer surface of the piston.
4) Apply a coat of specified grease to the boot, and
fit to the groove on the ends of the cylinder.
Grease:
NIGLUBE RX-2 (Part No. K0779GA102)
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 a coat of specified grease to the lock pin
and guide pin outer surface, cylinder inner surface,
and boot grooves.
Grease:
NIGLUBE RX-2 (Part No. K0779GA102)
(1) Place a wood block of 30 mm (1.18 in) width.
(1) Piston seal
(1)BR-00026
BR-00240
(1)
BR-00027
(1) Piston
(2) Piston boot
(1) Piston
(2) Piston boot
(3) Caliper body
(4) Piston seal
BR-00242
(1)
(2)
BR-00243
(1)
(2)
(3)
(4)

BR-18
Front Disc Brake Assembly
BRAKE
8) Insert the lock pin and guide pin boot into the
support.
E: INSPECTION
1) Repair or replace the faulty parts.
2) Check the caliper body and piston for uneven
wear, damage or rust.
3) Check the rubber parts for damage or deteriora-
tion.
(1) Pin boot
(2) Lock pin or guide pin
(3) Grease applied area
BR-00362
(1)(2)
: (3)

BR-19
Rear Brake Pad
BRAKE
5. Rear Brake Pad
A: REMOVAL
1) Lift-up the vehicle, and then remove the rear
wheels.
2) Remove the brake hose bracket.
3) Remove the caliper bolt.
4) Raise the caliper body and support it.
NOTE:
Do not disconnect the brake hose from the caliper
body.
5) Remove the pad.
B: INSTALLATION
1) Apply a thin coat of Molykote M7439 to the pad
clip.
2) Apply a thin coat of Molykote AS880N (Part No.
K0777YA010) to the contact surface between the
pad and shim.
3) Install the pad to support.
4) Install the caliper body to the support.
Tightening torque:
27 N·m (2.8 kgf-m, 19.9 ft-lb)
C: INSPECTION
Check thickness A of the pad.
NOTE:
•Always replace the pads on both sides as a set.
•Replace pad clips if they are twisted or worn.
•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.
•Replace the pad if there is oil or grease on it.
BR-00497
BR-00032
Pad thickness mm (in)Specification 11.0 (0.433)
Wear limit 1.5 (0.059)
BR-00345
A
BR-00016

BR-20
Rear Disc Rotor
BRAKE
6. Rear Disc Rotor
A: REMOVAL
1) Lift-up the vehicle, and then remove the rear
wheels.
2) Release the parking brake.
3) Remove the two mounting bolts, and remove the
rear disc brake assembly.
4) Suspend the rear disk brake assembly so that
the hose is not stretched.
5) Remove the rear disk brake rotor.
NOTE:
If the disc rotor is difficult to remove, try the follow-
ing two methods in order.
(1) Turn the adjusting screw using a flat tip
screwdriver until the brake shoe moves ade-
quately away from the disc rotor.
(2) If it is difficult to remove the disc rotor from
the hub, drive an 8 mm bolt into the threads B of
the rotor, then remove the rotor.
B: INSTALLATION
1) Install in the reverse order of removal.
Tightening torque:
66 N·m (6.7 kgf-m, 48.7 ft-lb)
2) Adjust the parking brake. <Ref. to PB-9, AD-
JUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>
C: INSPECTION
1) Check the rear wheel bearing play and axle hub
runout before inspecting the disc rotor runout limit.
<Ref. to DS-23, 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. Rotate the disc
rotor to check runout. If the disc rotor runout ex-
ceeds the limit, replace with a new disc rotor. After
grinding, check disk rotor thickness according to
step 4).
Disc rotor runout limit:
0.05 mm (0.0020 in)
(1) Adjusting screw
(2) Cover
(3) Flat tip screwdriver
(4) Disc rotor
PB-00092
(1)
(4)
(2)
(3)
PB-00094
B
A
BR-00018
BR-00037

BR-21
Rear Disc Rotor
BRAKE
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 the disc
rotor exceeds the service limit, replace with a new
disc rotor.
Specification LimitDisc rotor
outer diameter
Disc rotor thick-
ness A
mm (in)
18 (0.71) 16 (0.63) 320 (12.59)
B
A
BR-00018

BR-22
Rear Disc Brake Assembly
BRAKE
7. Rear Disc Brake Assembly
A: REMOVAL
CAUTION:
Do not allow brake fluid to come in contact with
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) Disconnect the brake hose from caliper body as-
sembly.
3) Remove the caliper lower 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 need not be removed when servicing
the caliper body assembly.
6) Remove mud and foreign matter from the caliper
body assembly and support.
CAUTION:
Be careful not to allow foreign matter to enter
the brake hose connector.
B: INSTALLATION
1) Install the support to the housing.
Tightening torque:
66 N·m (6.7 kgf-m, 48.7 ft-lb)
2) Apply a thin coat of Molykote M7439 to the pad
clip.
3) Apply a thin coat of Molykote AS880N (Part No.
K0777YA010) to the contact surface between the
pad and shim.
4) Install the pad to support.
5) Install the caliper body to the support.
Tightening torque:
27 N·m (2.8 kgf-m, 19.9 ft-lb)
6) Connect the brake hose using a new brake hose
gasket.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
7) Bleed air from the brake system.
C: DISASSEMBLY
1) Remove the piston boot.
2) Place a wooden block in the caliper body as
shown in the figure to prevent the piston from jump-
ing out and being damaged.
3) Gradually apply compressed air via the brake
hose installation hole to push the piston out.
BR-00498
BR-00345
(1) Place a wood block of 30 mm (1.18 in) width.
BR-00041
(1)BR-00042

BR-23
Rear Disc Brake Assembly
BRAKE
4) Remove the piston seal from caliper body cylin-
der.
CAUTION:
Do not damage the cylinder and piston seal
groove.
5) Remove the lock pin sleeve and boot from cali-
per body.
6) Remove the guide pin boot.
D: ASSEMBLY
1) Clean the inside of the caliper body using brake
fluid.
2) Apply a coat of brake fluid to piston seal and in-
stall piston seal in the groove on caliper body.
3) Apply a coat of brake fluid to the inner surface of
cylinder and the entire outer surface of the piston.
4) Apply a coat of specified grease to the boot and
fit to the groove on the ends of cylinder.
Grease:
NIGLUBE RX-2 (Part No. K0779GA102)
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 a coat of specified grease to the guide pin,
outer surface, sleeve outer surface, cylinder inner
surface, and boot grooves.
Grease:
NIGLUBE RX-2 (Part No. K0779GA102)
8) Install the guide pin boot to the support.
9) Install the lock pin boot to support, and then in-
sert the lock pin sleeve into the specified position.
E: INSPECTION
1) Repair or replace the faulty parts.
2) Check the caliper body and piston for uneven
wear, damage or rust.
3) Check the rubber parts for damage or deteriora-
tion.
(1) Piston
(2) Piston boot
(3) Caliper body
(4) Piston seal
BR-00043
BR-00243
(1)
(2)
(3)
(4)
(1) Pin boot
(2) Lock pin or guide pin
(3) Grease applied area
BR-00362
(1)(2)
: (3)

BR-24
Master Cylinder
BRAKE
8. Master Cylinder
A: REMOVAL
CAUTION:
Do not allow brake fluid to come in contact with
vehicle body. If it does, wash off with water and
wipe away completely.
1) Drain brake fluid from the reservoir tank com-
pletely.
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 from the brake booster.
B: INSTALLATION
1) Install in the reverse order of removal.
Tightening torque:
Master cylinder mounting nut
25 N·m (2.5 kgf-m, 18.4 ft-lb)
Brake pipe
19 N·m (1.9 kgf-m, 14.0 ft-lb)
CAUTION:
Be sure to use recommended brake fluid.
2) Bleed air from brake system. <Ref. to BR-31,
PROCEDURE, Air Bleeding.>
C: REPLACEMENT
1) Remove mud and dirt from the surface of brake
master cylinder.
2) Secure the master cylinder in a vise.
NOTE:
To avoid damaging the master cylinder, place be-
tween aluminum plates or other material when
holding with a vise.
3) Remove the pin which secures the master cylin-
der and reservoir tank, then remove the reservoir
tank and seal.
4) While pushing in the primary piston, remove the
C-ring using pliers.
5) While pushing in the primary piston, remove the
straight pin from the port on the reservoir tank at-
tachment location using a magnet pick-up tool.
6) Extract the primary piston assembly and sec-
ondary piston assembly straight out while taking
care not to scratch the inner surface of the cylin-
ders.
7) Clean the inside of master cylinder with brake
fluid. Check the inside of the cylinder for damage,
deformation and wear. Replace the master cylinder
as assembly if faulty.
8) Apply brake fluid to the inner surface of master
cylinder and piston assembly.
9) Make sure that the inner surface of master cylin-
der and the piston assembly are free of foreign
matter. Install the primary piston assembly and the
secondary piston assembly to master cylinder,
while taking care not to scratch the master cylinder
inner surface.
10) While pushing-in the primary piston, install the
cylinder pin.
BR-00499
(1) Straight pin
BR-00169
(1)
BR-00069

BR-25
Master Cylinder
BRAKE
11) While pushing-in the primary piston, install the
C-ring to the groove using pliers.
CAUTION:
Make sure the C-ring is installed to the groove
securely.
12) Install the seal to reservoir tank.
13) Install the reservoir tank to the master cylinder,
and secure with pin.
D: INSPECTION
Inspect for oil leakage from the master cylinder.
NOTE:
After replacing the piston kit, if an oil leakage is
found even though there is no damage or scratches
on the inside of the cylinder, the master cylinder in-
ner wall may be worn. In this case, replace the
master cylinder as an assembly.
(1) Seal
BR-00169
(1) BR-00072

BR-26
Brake Booster
BRAKE
9. Brake Booster
A: REMOVAL
1) Remove or disconnect the following parts in the
engine compartment.
(1) Remove the brake master cylinder.
(2) Disconnect the vacuum hose from brake
booster.
2) Remove the following parts from the pedal
bracket.
(1) Snap pin and clevis pin
(2) 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 res-
in portion as indicated by “P” may become
damaged.
(1) Nut
(2) Clevis pin
(3) Snap pin
(4) Operating rod
(1)
(3)
(4)
(2)
BR-00073
(1) Force
(1)
P
BR-00075