- 1). Check the fluid level in the brake master cylinder. If it is above half-full, remove fluid from the master cylinder using a clean turkey baster, until it is only half-full. Transfer this fluid to a small container.
- 2). Loosen, but do not remove, the Subaru's front lug nuts with a ratchet and socket or tire iron.
- 3). Raise the front of the Outback with a floor jack. Place jack stands under the Outback's subframe and lower the vehicle until only the stands support its weight.
- 4). Remove the front lug nuts and pull the wheels from the vehicle.
- 5). Compress the brake caliper piston by positioning an 8-inch C-clamp over the caliper so the screw side touches the outer brake pad and the fixed side touches the rear of the caliper. Tighten the C-clamp until the clamp stops moving. Remove the C-clamp.
- 6). Remove the two caliper bolts on the rear of the brake caliper with a ratchet and socket. Hold the caliper bolt sleeves with a combination wrench to keep them from rotating with the bolts, if needed.
- 7). Pull the caliper off of the caliper bracket and hang it, using a bungee strap, from a nearby suspension component. Never allow the caliper to hang by its hose, as this may damage the brake hose.
- 8). Grab the brake pads and pull them out of the caliper bracket. Remove the two bolts from the rear of the caliper bracket and pull it from the vehicle.
- 9). Grab the rotor and pull it off of the vehicle. If the rotor seems stuck on the vehicle, tap the rotor with a rubber mallet to free it.
- 10
Close the micrometer's jaws and press the "Zero" or "Reset" button to calibrate it. Place the micrometer over the rotor's disc and measure its thickness in four locations. Take note of the thinnest and thickest measurements. - 11
Check the condition of the rotor's disc for imperfections, such as: a mirror-like shine, hot spotting or gouges. Also compare the difference between the thickest measurement taken from the rotor and the thinnest measurement taken -- this is the rotor's run-out. If imperfections exist, or the rotor's run-out exceeds 0.003 inches, the rotor needs resurfaced or replaced. - 12
Take the rotor to a local machine shop and have it resurfaced if its thinnest measurement is thicker than 0.870 inches, known as the minimal machining thickness, and has any imperfections. If the rotor is thinner than the minimal machining specification and shows imperfections, replace the rotor. - 13
Replace the rotor, regardless of its condition, if its thinnest measurement is thinner than the discard specification stamped on the rotor. - 14
Install the new, old or resurfaced rotor on the Outback. - 15
Clean the metal shims on the caliper bracket -- where the pads slide in -- with a wire brush and apply a thin coat of disc brake grease to them. Reinstall the caliper bracket and tighten the two bolts to 50 to 65 foot-pounds with a torque wrench and a socket. - 16
Apply a thin coat of disc brake grease to the rear of the brake pads. Install the new brake pads into the caliper bracket. - 17
Slide the caliper over the brake pads and hand-tighten the caliper bolts. Torque the caliper bolts to 25 to 32 foot-pounds, if fitted with a dual-piston caliper, and 16 to 23 foot-pounds on a single-piston caliper, with a torque wrench and socket. Hold the caliper bolt sleeve with a combination wrench while tightening the bolt to prevent the sleeve from turning with the bolt, if needed. - 18
Repeat steps 4 through 16 for the brakes on the other side of the Outback. - 19
Reinstall the Outback's wheels and hand-tighten the lug nuts. - 20
Raise the Outback off of the jack stands with a floor jack, and pull the stands from under the vehicle. Lower the Subaru to the ground. - 21
Tighten the Subaru's lug nuts to 72 foot-pounds with a torque wrench and a socket. - 22
Press and release the brake pedal until it feels firm. - 23
Check the brake fluid level in the master cylinder and add new fluid until the level is at the "Max" line on the reservoir. - 24
Take the old brake fluid to a used automotive fluid recycling center for proper disposal. Many auto parts stores perform this task free of charge.
previous post