| Brake booster installation [message #76581] |
Sun, 14 March 2010 05:35  |
Ken Burton
Messages: 10030
Registered: January 2004
Location: Hebron, Indiana
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I watched Dan install his brake booster in about 15 minutes at Quartzsite. So, I decided it was time to finally install mine and return the core to Jim K.
Wow, 3 hours later I finally got it off. It turns out Dan has an after-market dash that allows easy access to the nuts that hold on the booster. Dan told me that I would need to grind away some of the plastic dash to get to the left lower bolt. I was determined to not cut on the dash. I got it out but the real question was how was I going to get the nuts back on the booster studs when I reinstalled it. I could not get my hands down in there. At that angle there was no tool I could think of that would hold the nuts correctly and allow me to turn them as the same time. I finally came up with the idea of gluing a couple of strings to the end of the studs. I would then allow the nuts and washers to travel down the strings to the studs. Then I would turn the nuts with a very long screwdriver.
Well, that did not work. I managed to get some of the glue in the threads. In cleaning out the threads prior to installing the booster the strings fell off.
Plan B.
I cleaned the threads on the mounting studs thoroughly so the nuts spun easily on them. Then I installed the booster. I put the washers and nuts on a long screwdriver. I put the screwdriver through the front hole in the dash and touched the end of each stud. Taking a second screwdriver I pushed each washer and nut into position on the end of the stud. Then I turned the nuts with a second screwdriver until the threads caught. After that it was a simple job of tightening them using a 1/4" drive 9/16" deep well with a u-joint on the extension. It is in and it probably would have been much easier had I cut the plastic. I just do not like butchering things up to get a job done.
After installation I turned on the key and and the vacuum pump kicked in to empty the booster. Then about 20 seconds later it did it again, and again, and again, and again.
OH man!!! Jim K. sold me a bad booster. I was not happy. I'll have to go through this all over again, return this booster and get another one. I went up front to check things out and while was there I twisted the check valve in the booster. Upon returning inside I turned on the key and the problem was gone. The check valve plugged into the front of the booster was not seated correctly.
Jim K. I apologize. The booster was fine. It was my installation of it was faulty.
Hopefully my above posting will help someone else attempting to do this same job. My best suggestion is to call Dan and get him to do it for you. He can do it in 15 minutes. I know as I watched and under my and Carl's supervision he got it done very quickly in Quartzsite.
Ken Burton - N9KB
76 Palm Beach
Hebron, Indiana
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