Brake Booster: Removal

WARNING: This page is about a different car, the 2012 Subaru Outback and 2012 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Do not allow brake fluid to come in contact with vehicle body. If it does, wash off with water and wipe away completely.

Disconnect the ground cable from battery.
Drain brake fluid from the reservoir tank completely.
Remove the master cylinder assembly.
CAUTION: In order to prevent the contact of the bracket and check valve, be sure to loosen the master cylinder mounting nut while holding the bracket with hand. Otherwise it may deform the bracket.

Fig 1: Removing Master Cylinder Assembly And Bracket
Courtesy of SUBARU OF AMERICA, INC.
1. Disconnect the fluid level gauge connector (a).
2. Disconnect the brake pipe (b).
3. Remove the nut (c), and slowly remove the master cylinder from the brake booster.
  
  Fig 2: Identifying Fluid Level Gauge Connector, Brake Pipe And Nut
  Courtesy of SUBARU OF AMERICA, INC.
Remove the brake booster.

CAUTION:

Do not disassemble the brake booster.
If external force (1) is applied from above when brake booster is placed in this position, the resin portion as indicated by "P" may become damaged.

Fig 3: Removing Brake Booster

Courtesy of SUBARU OF AMERICA, INC.

Remove the clamp and remove the vacuum hose.

Fig 4: Identifying Vacuum Hose And Clamp
Courtesy of SUBARU OF AMERICA, INC.
Remove the clips, and remove the instrument panel side cover LH.

Fig 5: Identifying Instrument Panel Side Cover LH Clips
Courtesy of SUBARU OF AMERICA, INC.
Remove the clips and data link connector, and remove the instrument panel lower cover under.

Fig 6: Identifying Instrument Panel Lower Cover Under And Clips
Courtesy of SUBARU OF AMERICA, INC.
Remove the screws and clips and release the claws, and remove the instrument panel lower cover while disconnecting the harness connectors.

Fig 7: Identifying Instrument Panel Lower Cover Screws And Clips
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Remove the bolts, and remove the knee guard panel.

Fig 8: Identifying Knee Guard Panel Bolts
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Remove the snap pin (a) and clevis pin (b), and remove the operating rod from the brake pedal.
NOTE:
- Use special care when handling the operating rod. If excessive force is applied to the operating rod, the angle may change by ±3°, and it may result in damage to power piston cylinder.
- Do not change the push rod length.
Fig 9: Removing Snap Pin And Clevis Pin
Courtesy of SUBARU OF AMERICA, INC.
Remove the nut and remove the brake booster.

NOTE:

Make sure that the booster shell and vacuum pipe are not subject to strong impacts.
Be careful not to drop the brake booster. If the brake booster is dropped accidentally, replace it.
Be careful when placing the brake booster on floor.

Fig 10: Locating Brake Booster Nuts

Courtesy of SUBARU OF AMERICA, INC.