AU1 3rd brake booster failure:(

[Stav]

Heheh no worries mate.I am having a shot at myself..I am a slacker sometimes.

[sly]

Originally Posted by stockoau

So whats involved in fitting the series 2 booster?

You need to drill 4 new holes in the firewall. The S1 booster has only 2 holes. The key is to make a good template for the bolt pattern of the S2 booster with the bolt holes in the right places relative to the piston. The piston fits the hole in the S1 firewall OK. And you need to line the template up right on the firewall to get the fluid reservoir at the same angle. The top pair of holes line up horizontally (as do the bottom ones) where the S1 holes are offset from horizontal.

Apart from that, you can disconnect the booster from the brake pedal easily enough if your fingers are strong enough to manipulate the R-clip, just take note of where the spacers/washers go to put it back together. If your car is non-ABS like mine you can get the master cylinder off the booster by just undoing the 2 nuts on the flange and unclipping the brake pipes from the firewall. My LPG lockoff was in the road so I had to move it too. There is some flex in the pipes so you can carefully move the m/cyl to the side to remove the booster.

If you have ABS you might have to disconnect the brake pipes from the master cylinder, not sure. If you have to disconnect the pipes do so with the master cylinder firmly bolted to the booster, the flare nuts bind up. I broke 1 flare nut spanner (13mm) then rounded off 2 of the 3 heads getting the m/cyl off to put a repair kit through it. Had to get a small Stillson (20mm??) in the end to get the flare nuts off.

Anyway it's not too hard to do this, then see my other reply above about the spacer... measure the depth of the cavity in the m/cyl piston, the length of the pushrod from the seal in the booster (maybe screw the adjusting screw all the way in first) and cut a soft metal spacer to fit the difference.

[GK]

Thanks for all that Sly. If you pull it apart again, do a "how to" with some digital pics. That would be a helpful resource.

Cheers,

GK

[sly]

Yeah I should have had the camera handy... when I get under the bonnet I tend to get very tightly focused. I hope never to have to pull it apart again, but then I've learned never to say never... never!

I still have the S1 booster, I might be able to do a couple of pics to show measuring the pushrod. If I don't get it done tomorrow it will be at least a week as I'll be away.