Brake Booster: Installation

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.

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

Fig 2: Identifying Snap Pin, Clevis Pin, Nut And Operating Rod
Courtesy of SUBARU OF AMERICA, INC.

NOTE: Apply a thin coat of KOPR-KOTE (Part No. 003603001) to the clevis pin.
Connect the vacuum hose to the brake booster.
Mount the master cylinder onto the brake booster.
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. Ref. to 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)

Fig 3: Identifying Stop Light Switch Clearance
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 brake does not drag.