caliper SUBARU TRIBECA 2009 1.G Service Workshop Manual

BR-4
General Description
BRAKE
B: COMPONENT
1. FRONT DISK BRAKE
(1) Caliper body (9) Support (16) Disc cover
(2) Air bleeder screw (10) Pad clip (17) Bushing
(3) Guide pin (Green) (11) Outer shim
(4) Pin boot (12) Inner shimTightening torque: N·m (kgf-m, ft-lb)
(5) Piston seal (13) Pad (Outside)T1: 8 (0.8, 5.8)
(6) Piston (14) Pad (Inside)T2: 27 (2.8, 19.9)
(7) Piston boot (15) Disc rotorT3: 120 (12.2, 88.5)
(8) Lock pin (Yellow)
BR-00490
(1)
(2)
(3)
(4)
(4)
(17)(10)
(16)
(15)
(5)
(6)(7)
(8)
T2
T3
(11)
(11)
(12)
(12)
(13)
(14)
(13)
T1
(9)

BR-5
General Description
BRAKE
2. REAR DISC BRAKE
(1) Caliper body (13) Outer pad (25) Secondary shoe return spring
(2) Air bleeder screw (14) Shim (26) Primary shoe return spring
(3) Guide pin (Green) (15) Shoe hold pin (27) Adjusting spring
(4) Pin boot (16) Cover (28) Adjuster
(5) Piston seal (17) Back plate (29) Brake shoe cup
(6) Piston (18) Retainer (30) Brake shoe spring
(7) Piston boot (19) Spring washer
(8) Support (20) Parking brake leverTightening torque: N·m (kgf-m, ft-lb)
(9) Lock pin (Yellow) (21) Parking brake shoe (Secondary)T1: 8 (0.8, 5.8)
(10) Bushing (22) Parking brake shoe (Primary)T2: 27 (2.8, 19.9)
(11) Pad clip (23) StrutT3: 37 (3.7, 27.2)
(12) Inner pad (24) Strut shoe springT4: 66 (6.7, 48.7)

BR-12
Front Brake Pad
BRAKE
2. Front Brake Pad
A: REMOVAL
1) Lift-up the vehicle, and remove the front wheels.
2) Remove the caliper bolt.
3) Raise the caliper body and support it.
NOTE:
Do not disconnect the brake hose from the caliper
body.
4) 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.
K0779YA010) to the contact surface between the
pad and pad inner shim.
3) Apply a thin coat of Molykote AS880N (Part No.
K0779YA010) to the three contact surfaces be-
tween inner shim and outer shim of outer pads.
BR-00339
BR-00012
BR-00340
BR-00238
BR-00341

BR-13
Front Brake Pad
BRAKE
4) Install the pad to support.
NOTE:
Install the pad indicator in proper direction.
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 dam-
aged, replace the brake pad.
5) 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.
•Replace the pad if there is oil or grease on it.
(1) LH – IN
(2) LH – OUT
(3) RH – IN
(4) RH – OUT
(5) Pad indicator
(6) Pad return spring
BR-00342
(5)
(6)
(6)
(1)
(2)
(3)
(4)(5)
(6)
(6)
(1) Pad return spring
(2) Suppor ting surface of pad clip
(3) Direction of brake rotor rotation
Pad thickness mm
(in)
Specification 11 (0.433)
Wear limit 1.5 (0.059)
BR-00483
(1)
(2)(3)
BR-00360
A

BR-14
Front Disc Rotor
BRAKE
3. Front Disc Rotor
A: REMOVAL
1) Lift-up the vehicle, and remove the front wheels.
2) Remove the caliper body and the support from
housing, and suspend it from the strut using a wire.
3) Remove the disc rotor.
NOTE:
If it is difficult to remove the disc rotor from the hub,
drive an 8 mm bolt into the threaded section (B) of
the rotor, then remove the rotor.
4) Remove mud and foreign matter from the caliper
body assembly and support.
B: INSTALLATION
1) Install the disc rotor.
2) Install the caliper body and the support to hous-
ing.
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
3) Install the front wheels.
C: INSPECTION
1) Check the front wheel bearing play and axle hub
runout before the inspection of disc rotor runout
limit.
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)
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.
BR-00017
B
A
BR-00018
Specification LimitDisc rotor
outer diameter
Disc rotor thick-
ness A
mm (in)
30 (1.18) 28 (1.10) 316 (12.44)
BR-00019
B
A
BR-00018

BR-15
Front Disc Brake Assembly
BRAKE
4. Front 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 remove the front wheels.
2) Remove the union bolt, and disconnect the
brake hose from the caliper body assembly.
3) Remove the bolt securing the lock pin to caliper
body.
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.
B: INSTALLATION
1) Install the support to the housing.
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 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 pad
and inner shim.
4) Apply a thin coat of Molykote AS880N (Part No.
K0779YA010) to the three contact surfaces be-
tween inner shim and outer shim of outer pads.
BR-00021
BR-00022
BR-00023
BR-00340
BR-00238
BR-00341

BR-16
Front Disc Brake Assembly
BRAKE
5) Install the pad to support.
NOTE:
Install the pad indicator in proper direction.
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 dam-
aged, replace the brake pad.
6) Install the caliper body to the support.
Tightening torque:
27 N·m (2.8 kgf-m, 19.9 ft-lb)
7) Connect the brake hose using a new brake hose
gasket.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
8) Bleed air from the brake system.
(1) LH – IN
(2) LH – OUT
(3) RH – IN
(4) RH – OUT
(5) Pad indicator
(6) Pad return spring
BR-00342
(5)
(6)
(6)
(1)
(2)
(3)
(4)(5)
(6)
(6)
(1) Pad return spring
(2) Suppor ting surface of pad clip
(3) Direction of brake rotor rotation
BR-00483
(1)
(2)(3)

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