Brake Booster: Installation

WARNING: This page is about a different car, the 2007 Subaru Outback and 2007 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.

Check and adjust the operating rod of brake booster.
Standard L:

136.3 mm (5.38 in)

If it is not within the specified value, adjust it by adjusting the brake booster operating rod.

Fig 1: Adjusting Brake Booster Operating Rod Length
Courtesy of SUBARU OF AMERICA, INC.
Mount the brake booster in position.
Connect the operating rod to brake pedal with clevis pin and snap pin.

Fig 2: Connecting Operating Rod To Brake Pedal
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Apply a thin coat of grease [SUNLIGHT 2 (Part No. 003602010)] to clevis pin.
Connect the vacuum hose to brake booster.
After replacing the O-ring with a new one, install the master cylinder to brake booster.

Fig 3: Installing Master Cylinder O-Ring
Courtesy of SUBARU OF AMERICA, INC.
Connect the brake pipes to master cylinder.
Connect the connector for brake fluid level gauge.
Measure the clearance between the threaded end of stop light switch and stopper.
If it is not within specified value, adjust it by adjusting the position of stop light switch. < Ref. to , ADJUSTMENT , Stop Light Switch. >

CAUTION: Be careful not to rotate the stop light switch.

Stop light switch clearance A:

0.3 mm (0.012 in)

Fig 4: Identifying Clearance Between Stop Light Switch Threaded End And Stopper
Courtesy of SUBARU OF AMERICA, INC.
Apply grease to the operating rod connecting pin to prevent it from wearing.
Bleed air from the brake system.
Tightening torque (Air bleeder screw):

8 N.m (0.8 kgf-m, 5.8 ft-lb)
Conduct road tests to ensure brakes do not drag.