Brake Booster: Installation

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

136.5 mm (5.38 in)

If it is out of specification, adjust it with the brake booster operating rod.

Fig 1: Identifying Brake Booster Operating Rod Dimension
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: Identifying Brake Booster Nuts
Courtesy of SUBARU OF AMERICA, INC.

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

Fig 3: Identifying O-Ring And Primary Piston
Courtesy of SUBARU OF AMERICA, INC.
Connect the brake pipes to the master cylinder.
Connect the connector of the brake fluid level gauge.
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 adjusting the position of the stop light switch. Refer 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 And Stopper
Courtesy of SUBARU OF AMERICA, INC.
Apply grease to the operating rod connecting pin to prevent it from wear.
Bleed air from brake system.
Tightening torque (air bleeder screw):

8 N.m (0.8 kgf-m, 5.8 ft-lb)
Perform a road test to make sure the brakes do not drag.