I've got a pinch tool like that one. Good idea on the vice grips and rubber hoses.

 

Did you use a scan tool for your throttle relearn?

 

Nice job. I found that on my early FB25 that I did not need to fully remove it to clean it. Issue for me was I did not want to undo the cooling hoses that are connected, mainly because on a previous vehicle one of those hoses would not seal properly after and required replacement. With the bolts for the TB removed there was room to fit a pan underneath it and clean both sides.
I am curious if anyone knows the purpose of that gasket?. It cant be to stop or catch debris.

 

The gasket is to stop any large particles from entering the intake. The air filter is for finer particles. I think it’s also for even air flow.
The relearn procedure is posted here somewhere. No scan tool necessary.

 

That was my guess but it would only stop something like a leaf very briefly and as you point out the air filter should prevent any debris from making it that far up the air stream. It seems to be it must serve some other purpose?

 

The filter also stops anything from falling in if you disconnect the plastic intake. 😉
I think it evens out the airflow as well.

 

Nice job and thanks for the great documentation with pictures! On my 2015 I did not remove it to clean it, just put a large rag under the TB propped it open with a wooden dowel and used a toothbrush with cleaner and a rag to finish scrubbing both sides of it and the bore clean. Is that mesh screen thing plastic, rubber, or? Is it also what's in the brown box that you labelled gasket? Used an inspection mirror with flashlight and don't recall seeing that in mine.

 

@Natedog
Yes, that is the TB gasket labeled.
it’s a metal screen with a hard rubber gasket Ring. You should have it on your TB unless someone previously didn’t replace it. It gets destroyed removing it.

The FSM calls for a new gasket any time that the TB is removed.
why is yours missing? All Subarus have a TB gasket. I’m surprised that you don’t have a vacuum leak.

 

Thanks, I've never had the TB off, will check it again next time I've got the intake snorkel off.