Availability of New Master Cylinder to Brake Booster Seal Kits To Address Hard Brake Pedal Feel – 2008-2020 Subaru

NHTSA ID Number: 10179422

Manufacturer Communication Number: 06-79-20

Summary

This bulletin announces availability of new master cylinder application shaft seals.

49 Affected Products

Vehicles

NUMBER: 06-79-20
DATE: 08/31/20

INTRODUCTION:

This bulletin announces availability of new master cylinder application shaft seals.  The seal is located on the back of the master cylinder but, its purpose is to retain vacuum inside the power brake (Master Vac) booster.  Over time and repeated washing of the engine / engine compartment, moisture can cause surface rust to develop on the booster at the insertion point of the master cylinder.  In some cases, this can result in a VERY slow loss of vacuum stored in the booster and cause the brake pedal to have a harder feel than what the operator may be used to after starting or restarting the engine.  Once the engine is started, stored vacuum in the booster is regenerated and brake pedal feel returns to normal as power assist is restored.

PRODUCTION CHANGE INFORMATION:

This bulletin will be revised with the starting VIN information for these new seal kits when it becomes available.

PART INFORMATION:

REMINDER: Always order the most up-to-date replacement parts based on the specific VIN being repaired.

The new Kits contain: 1 new seal, 1 packet of SILICONE grease, 1 packet of FLUORINE grease and Instructions.

SERVICE PROCEDURE / INFORMATION:

REMINDER:  Customer satisfaction and retention starts with performing quality repairs.

Although procedures for master cylinder removal / replacement and seal replacement are unchanged, there is a new procedure for application of the 2 greases supplied in the kit which MUST be followed prior to reinstalling the Master Cylinder onto the booster.  Always refer to the applicable Service Manual and review the full requirements of the repair being performed.  Service Manual procedures contain information critical to performing effective repairs the first time, every time.  This includes but is not limited to important SAFETY precautions, proper inspection criteria, necessary special tools, required processes and related one-time-use parts needed for a complete and lasting repair.

• CAREFULLY remove the master cylinder assembly from the brake booster following the procedure in the applicable Service Manual. IMPORTANT REMINDER: Always cover any surrounding painted surfaces with clean cloths or a fender cover to protect them from any spilled brake fluid.

• Remove the existing seal from the back of the master cylinder OR from its bore in the front of the brake booster and discard.

• Using a mild solvent on a clean shop cloth, clean any surface rust, grease or contamination from the seal bore on the front of the booster, master cylinder primary piston, machined surfaces of the master cylinder where the New Seal will be installed and the common mounting surfaces where the master cylinder mounts to the booster.

GREASE APPLICATION:  Figures 1 and 2 below show where to CAREFULLY apply the two new greases included in the Seal Kit.  The FLUORINE grease packet is labeled for easy identification.

Apply the FLUORINE grease to:

• The New Seal bore of the brake booster
• The OUTSIDE diameter of the New Seal
• Use ALL the FLUORINE grease supplied in the packet.

Apply the SILICONE grease to:

• The outside of the master cylinder primary piston
• The INSIDE diameter of the New Seal (sealing for the primary piston surface).

VERY IMPORTANT:  When applying the greases and during reassembly, DO NOT allow them to come into contact with each other.

• CAREFULLY Install the New Seal by hand until it is fully seated against the back of the master cylinder as shown in Figure 1 above.

• CAREFULLY reassemble the master cylinder onto the booster in reverse order of removal and tighten the retaining nuts as follows:

• • H4 models: 13 N·m (1.3 kgf-m, 9.6 ft-lbs.)

• • H6 models: 25 N·m (2.5 kgf-m, 18.4 ft-lbs.)

• Reinstall the master cylinder in reverse order of removal and bleed the brake system following the procedures in the applicable Service Manual.

• ALWAYS road test the vehicle when repairs are complete to confirm proper brake system operation before releasing it back to the customer.

WARRANTY / CLAIM INFORMATION:

For vehicles within the Basic New Car Limited Warranty period or covered by an active Subaru Added Security Classic or Gold plan, this repair may be submitted using the following claim information:

IMPORTANT REMINDERS:

• SOA strongly discourages the printing and/or local storage of service information as previously released information and electronic publications may be updated at any time.
• Always check for any open recalls or campaigns anytime a vehicle is in for servicing.
• Always refer to STIS for the latest service information before performing any repairs.

1 Associated Document

Manufacturer Communications

NUMBER: 06-79-20
DATE: 08/31/20

https://www.nhtsa.gov/recalls?nhtsaId=10179422

MC-10179422-0001.pdf 1345.411KB

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