2002-2006 Subaru Baja Parking Brake Problems and Adjustment

By Core Brake Parts Tech Team — Circleville, OH warehouse

The Subaru Baja uses rear disc brakes with a small drum brake built into the hat of each rear rotor, and that drum is what the parking brake lever actually applies. When a Baja's hand brake pulls up too far, fails to hold on a hill, or drags, the fix is almost always a two-part adjustment: set the shoe clearance at each rear wheel first, then set the lever stroke at the cable. Subaru's target is a lever that locks at 7 to 8 notches with a firm, steady pull.

How the Baja Parking Brake Works

The Baja shares its chassis and rear brake layout with the Legacy and Outback of the same era. Subaru's factory service manual for that platform describes the parking brake as mechanical, acting on the rear brakes, of the "drum in disc" type. The hydraulic rear caliper and pads handle normal stopping. Inside the rotor hat sits a separate pair of parking brake shoes mounted on the back plate, with a lever, strut, return springs, hold-down springs and a manual star-wheel adjuster.

When you pull the center-console lever, it tensions a front cable that runs to an equalizer, which splits the pull between the left and right rear cables. Each rear cable pulls a lever on the shoe assembly, which spreads the shoes out against the inside of the rotor hat.

Two things make this system different from a typical rear drum brake:

• It does not self-adjust. Subaru lists the clearance adjustment as manual. As the shoes and the drum surface wear, the lever travel slowly grows until someone adjusts it.
• It only works when you use it. Because the shoes are not used for normal stopping, the adjuster and cables can sit untouched for years and corrode in place, especially on trucks driven in salted winter conditions.

Factory Specifications

The numbers below come from Subaru's factory service manual for the shared Legacy platform and from the 2003 Baja owner's manual. Measure before you buy parts.

Subaru also specifies that the parking brake shoes be replaced on the left and right sides at the same time.

Common Symptoms and What Causes Them

Lever pulls up too high or will not hold on a hill

This is the most common complaint. If the lever passes 8 notches before it gets firm, the shoes have too much clearance. Typical causes: shoe clearance never adjusted after pad or rotor work, normal lining wear, a stretched or partly seized cable, or linings worn below the 1.5 mm limit. Adjusting the cable alone to take up slack from worn shoes is a common shortcut that leaves the brake weak.

Rear brake drag, heat or a burning smell

Subaru's diagnostic table lists four causes of parking brake drag: a maladjusted lever, a cable that does not move, maladjusted shoe clearance, or a faulty return spring. A seized cable is the one to rule out first. Pull and release the lever with the rear wheels off the ground and check that both wheels spin freely after release. If the shoes are adjusted so tight that the rotor will not spin freely, the heat can distort the rotor and damage the wheel bearing.

Noise from the rear

A scraping or rattling noise from inside the rotor hat usually points to a faulty return spring or shoe hold-down spring. Subaru's remedy for both is replacement. A loose spring can also let a shoe rub, which feeds back into the drag symptom above.

Brake warning light stays on

On the Baja, the brake system warning light comes on whenever the parking brake is applied with the ignition on. If the light stays on after the lever is fully released, confirm the lever is all the way down, then check the brake fluid level. The owner's manual warns that driving with the light on is dangerous and says to have the brakes inspected immediately.

How to Adjust the Parking Brake

Do the shoe clearance first, then the lever. Adjusting only the lever is the reason many Bajas end up with a brake that holds for a while and then goes slack again.

Step 1: Shoe clearance at each rear wheel

1. Release the parking brake fully and back off the cable adjusting nut at the lever so the cables are slack.
2. Raise the rear of the truck on stands and remove the rear wheels.
3. Remove the rubber adjusting hole cover from the back plate.
4. Using a slot-type screwdriver, turn the adjusting screw until the shoes are in close contact with the rotor and it cannot be turned by hand.
5. Turn the adjusting screw back 3 or 4 notches, per the factory procedure. The rotor should now spin freely with no heavy drag.
6. Reinstall the hole cover and repeat on the other side.

Step 2: Lever stroke at the console

1. Remove the console cover to reach the adjusting nut and lock nut at the base of the lever.
2. Pull the lever forcibly 3 to 5 times to seat the cables and shoes.
3. Turn the adjusting nut until the lever locks at 7 to 8 notches with a firm pull, then tighten the lock nut to the specified torque.
4. Release the lever and confirm both rear wheels spin freely.

The Baja owner's manual adds a caution worth repeating: pulling the lever too forcefully can lock the rear wheels, so pull it up slowly and firmly.

Replacing Parking Brake Shoes

If the linings measure under the service limit, are contaminated with grease or oil, or the rotor hat is worn past 171 mm or scored, adjustment will not fix it. To reach the shoes, remove the rear caliper (hang it so the hose is not stretched) and pull the rotor. If the rotor will not come off, back the adjuster off through the hole first; if it is seized to the hub, Subaru's procedure is to thread 8 mm bolts into the holes provided in the rotor to push it off.

When reassembling, the factory manual calls for brake grease on the shoe-to-back-plate contact pads, the anchor and adjuster contact points, and the lever and strut contacts, while keeping grease off the linings. Do not mix up the left and right parking levers or struts. New brake hardware kits are a good idea on any Baja old enough to need shoes; tired springs are a direct cause of drag and noise.

New shoes need a break-in. Subaru's procedure: drive at about 22 mph, hold the release button in and pull the lever gently, drive about 0.12 mile that way, then let the brake cool for 5 to 10 minutes and repeat once. After break-in, adjust the shoes and lever again. Replacement shoes are in our brake shoes collection.

What to Do at the Same Time

• Rear rotors: the inside of the rotor hat is the parking brake drum. Any time you install new rear brake rotors, re-adjust the shoe clearance, because the new drum surface will not match the old one.
• Rear pads: the rear caliper has to come off to reach the parking shoes anyway, so it is a natural time to inspect the rear pads. For a Baja that tows or carries weight in the bed, the EBC Yellowstuff rear pad set for the 2002-2006 Baja and the EBC Redstuff rear pads both fit, and Baja Sport owners can use the Hawk HPS 5.0 rear pads for the 2004-2006 Baja Sport.
• Cables: inspect the inner cable for damage and rust and the outer cable and boots for bends and cracks. Subaru's inspection calls for replacing a cable that is damaged, rusty or does not operate smoothly.

Difficulty: a shoe clearance and lever adjustment is an easy job for anyone who can safely lift the truck and pull wheels. Replacing shoes is moderate; the springs take patience and the rotor may be rusted to the hub.

Frequently Asked Questions

How many clicks should a Subaru Baja parking brake take?

Subaru specifies 7 to 8 notches with about 44 lb of pull on the lever. More than that means it needs adjustment; noticeably fewer can mean the shoes are too tight and may drag.

Does the Baja parking brake adjust itself?

No. The drum-in-hat parking brake on the Baja is manually adjusted through a hole in the back plate. The rear disc pads adjust automatically, but the parking shoes do not.

Can I just tighten the cable at the lever?

You can, but it should come second. Set the shoe clearance at the wheels first, then set the lever stroke. Taking up worn-shoe clearance with the cable alone gives a weaker brake that goes slack again quickly.

Why does my Baja parking brake stick after sitting all winter?

The cables and adjuster are exposed to road salt and water, and because the parking brake sees less use than the service brake, they can corrode in place. A cable that does not move is one of the causes Subaru lists for parking brake drag. Replace a rusty or binding cable rather than forcing it.

Do I need to adjust the parking brake after new rear rotors?

Yes. The inside of the rotor hat is the parking brake drum, so a new rotor changes the shoe clearance. Adjust the shoes before you set the lever stroke.

Sources

1. Subaru 2003 Legacy Service Manual, Parking Brake section - drum-in-disc design, manual adjustment, drum and lining specs, adjustment and break-in procedures, lock nut torque, diagnostic table
2. Subaru 2003 Legacy Service Manual, Brake section - rear disc brake layout including the parking shoe assembly
3. 2003 Subaru Baja Owner's Manual, Parking Brake Stroke - 7 to 8 notches at 44 lb and the caution against pulling the lever too forcefully
4. 2003 Subaru Baja Owner's Manual, Brake System Warning Light - warning light behavior with the parking brake applied
5. Blingstrom: Subaru parking brake adjustment (disc brakes) - access through the rotor hat and the heat and bearing risk of over-tight shoes