2009 SUBARU TRIBECA ECU

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. 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.
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-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. 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-27
Brake Booster
BRAKE
B: INSTALLATION
1) Check and adjust the operating rod of the brake
booster.
Specification L:
137.6 mm (5.42 in)
If it is out of specification, adjust it with the brake
booster operating rod.
2) Mount the brake booster in position.
3) Connect the operating rod to brake pedal with
the clevis pin and snap pin.
NOTE:
Apply a thin coat of SUNLIGHT 2 (Part No.
003602010) to the clevis pin.
4) Connect the vacuum hose to the brake booster.
5) Mount the master cylinder onto the brake boost-
er.
6) Connect the brake pipes to the master cylinder.
7) Connect the connector of the brake fluid level
gauge.
8) Measure the clearance between the threaded
end of the stop light switch and the stopper.
If it is not within the specification, adjust it by adjust-
ing the position of the stop light switch. 38, ADJUSTMENT, Stop Light Switch.>
CAUTION:
Be careful not to rotate the stop light switch.
Stop light switch clearance A:
0.8 mm (0.031 in)
9) Apply grease to the operating rod connecting pin
to prevent it from wear.
10) Bleed air from brake system.
Tightening torque (air bleeder screw):
8 N·m (0.8 kgf-m, 5.8 ft-lb)
11) Perform a road test to make sure the brake
does not drag.
C: INSPECTION
1. OPERATION CHECK (WITHOUT GAUG-
ES)
CAUTION:
When checking operation, be sure to apply the
parking brake securely.
Check without gauges
This method can not determine exactly what part is
defective. But it is possible to identify the general
type of defect if the following inspection is per-
formed.
(1) Nut
(2) Clevis pin
(3) Snap pin
(4) Operating rod
L
BR-00076
(1)
(3)
(4)
(2)
BR-00073
BR-00500
A

BR-28
Brake Booster
BRAKE
Air tightness check
Start the engine, and idle it for 1 to 2 minutes, then
turn it OFF. Depress the brake pedal several times
applying the normal pedal force. The pedal stroke
should be the longest at the 1st depression, and it
should become shorter at each successive depres-
sion. If no change occurs in the pedal height when
pressed, the brake booster is faulty.
NOTE:
•In case of defective operation, inspect the condi-
tion of the check valve and vacuum hose as well.
•Replace them if faulty, and perform the test
again.
•If the defective condition is not improved, check
accurately using a gauge.
Operation check
1) While the engine is OFF, depress the brake ped-
al several times applying the same pedal force, to
check for a change in pedal height.
2) With the brake pedal pressed, start the engine.
3) As the engine starts, the brake pedal should
move slowly toward the floor. If the pedal height
does not change, the brake booster is faulty.
NOTE:
If faulty, perform an accurate check with a gauge.
Loaded air tightness check
Depress the brake pedal while the engine is run-
ning, and turn the engine OFF while the pedal is de-
pressed. Keep the pedal depressed for 30
seconds. If the pedal height does not change, the
function of brake booster is normal. If the pedal
height increases, it is faulty.
NOTE:
If faulty, perform an accurate check with a gauge.
2. OPERATION CHECK (WITH GAUGE)
CAUTION:
When checking operation, be sure to apply the
parking brake securely.
Check with gauge
Connect the gauge as shown in the figure. After
bleeding air from the pressure gauge, perform the
checks.
(1) Normal
(2) Not OK
(3) 1st
(4) 2nd
(5) 3rd
(1) When engine is stopped
(2) When engine is started
(1)
(3)(4)
(5)
(2)
BR-00080
(1) (2)
BR-00081
(1) Pressure gauge
(2) Vacuum gauge
(3) Adapter hose
(4) Vacuum hose
(5) Pedal force gauge
(1) (2)
(3) (4) (5)
BR-00082

BR-31
Air Bleeding
BRAKE
11.Air Bleeding
A: PROCEDURE
CAUTION:
•Do not let brake fluid come into contact with
the painted surface of the vehicle body. Wash
away with water immediately and wipe off if it is
spilled by accident.
•Avoid mixing brake fluids of different brands
to prevent fluid performance from degrading.
•Be careful not to allow dirt or dust to enter the
reservoir tank.
1. MASTER CYLINDER
NOTE:
•When the master cylinder is disassembled or the
reservoir tank is empty, bleed the master cylinder.
•If bleeding of the master cylinder is not neces-
sary, omit the following procedures, and perform
bleeding of the brake line. LINE, PROCEDURE, Air Bleeding.>
1) Fill the reservoir tank of the master cylinder with
brake fluid.
NOTE:
While bleeding air, keep the reservoir tank filled
with brake fluid to prevent entry of air.
2) Disconnect the brake line at primary and sec-
ondary sides.
3) Wrap the master cylinder with a plastic bag.
4) Depress the brake pedal slowly and hold it.
5) Plug the outlet plug with your finger, and then re-
lease the brake pedal.
6) Repeat the step 4) and 5) several times.
7) Remove the plastic bag.
8) Install the brake pipe to the master cylinder.
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
9) Bleed air from the brake line. BRAKE LINE, PROCEDURE, Air Bleeding.>
2. BRAKE LINE
1) When the master cylinder is disassembled or the
reservoir tank is empty, bleed the master cylinder
before bleeding the brake line. MASTER CYLINDER, PROCEDURE, Air Bleed-
ing.>
2) Fill the reservoir tank of the master cylinder with
brake fluid.
NOTE:
While bleeding air, keep the reservoir tank filled
with brake fluid to prevent entry of air.
3) Attach one end of the vinyl tube to the air bleeder
and the other end to the brake fluid container.
4) Depress the brake pedal several times, and
keep it pressed.
5) Loosen the air bleeder screw to drain brake fluid.
Tighten the air bleeder quickly, and release the
brake pedal.
6) Repeat the steps 4) to 5) until there are no more
air bubbles in the vinyl tube.
7) Repeat the steps from 2) to 6) above to bleed air
from each wheel.
NOTE:
Perform the operation in the order from closest
wheel cylinder to the master cylinder.
8) Securely tighten the air bleeder screws.
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
9) Check that there are no brake fluid leaks in the
entire system.
BR-00090
BR-00091
BR-00087

BR-34
Brake Hose
BRAKE
B: INSTALLATION
1. FRONT BRAKE HOSE
1) Secure the brake hose to strut mount.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
2) Install the brake hose to the caliper using a new
gasket.
Tightening torque (union bolt):
18 N·m (1.8 kgf-m, 13.0 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 (1.5 kgf-m, 10.8 ft-lb)
7) Bleed air from brake system.
2. REAR BRAKE HOSE
1) Install the brake hose bracket.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
2) Connect the brake hose to the brake pipe.
3) Insert the clamp to secure brake hose.
4) Install the brake hose to rear brake caliper using
a new gasket.
Tightening torque (union bolt):
18 N·m (1.8 kgf-m, 13.0 ft-lb)
5) Tighten the flare nut to the specified torque.
Tightening torque (brake pipe flare nut):
15 N·m (1.5 kgf-m, 10.8 ft-lb)
6) Bleed air from the brake system.
C: INSPECTION
Make sure there are no cracks, breakage or dam-
age on hoses. Check the joint for fluid leakage. If
any cracks, breakage, damage or fluid leakage is
found, repair or replace the hose.
(1) Brake hose bracket
(2) Brake hose
BR-00021
BR-00503
(1)
(2)
(1) Brake pipe
(2) Brake hose
(3) Brake hose clamp
(1) Brake hose
BR-00502
(1)(2)(3)
BR-00501
(1)

BR-36
Brake Pedal
BRAKE
14.Brake Pedal
A: REMOVAL
1) Remove the steering shaft.
2) Disconnect the connector (stop light switch etc.)
from the pedal bracket.
3) Remove the clevis pin which secures the lever
and push rod.
4) Remove the bolt and nut which secures the ped-
al bracket.
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Always use a new clevis pin.
2) Check the brake pedal after installation. BR-36, INSPECTION, Brake Pedal.>
C: INSPECTION
1) Move the brake pedal pads in a horizontal direc-
tion with a force of approx. 10 N (1 kgf, 2 lb), 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:
Limit
Less than 4.0 mm (0.157 in)
2) Check the position of the pedal pad.
Pedal height L:
155 — 175 mm (6.10 — 6.89 in)
Brake pedal free play A:
0.5 — 2 mm (0.02 — 0.08 in) [When pulling the
brake pedal upward with a force of less than
10 N (1 kgf, 2 lb).]]
3) If it is not within the specification, adjust it by ad-
justing the brake booster operating rod length.
(1) Clevis pin
(2) Snap pin
(3) Operating rod
(2)
(3)
(1)
BR-00351
(1) Brake pedal
(1) Stop light switch
(2) Mat
(3) Toe board
(4) Brake booster operating rod