brake booster replacement
Thread Starter
Instructor
Joined: May 2006
Posts: 194
Likes: 2
From: Worcester Mass
brake booster replacement
Hey guys, I'm struggling to get the brake booster out in my 02 Z06. I finally got the nuts off but now the star washers are stopping me. I can't see them so I'm assuming they are between the aluminum frame and the fiberglass. When I try to pull it looks like glass is going to break. Can't really pry without damaging the fiberglass either. I can't pull straight out, just can't get the angle. Any ideas that might help?
Team Owner
Joined: Sep 2001
Posts: 23,283
Likes: 906
From: Lake Elsinore, CA
Have you removed all the hardware from the inside such as the pin and retainer from the brake pedal pushrod, the steering column screw (if you have the telescoping column) and the brake booster mounting nuts and washers from the booster studs? If so, the manual lists these steps to get the booster out.
In order to remove the booster from the cowl, perform the following steps:
-In order to release the booster mounting studs from the push-on nuts, move booster from side to side.
-Pull the booster straight out.
-Remove the brake booster and seal from the cowl.
In order to remove the booster from the cowl, perform the following steps:
-In order to release the booster mounting studs from the push-on nuts, move booster from side to side.
-Pull the booster straight out.
-Remove the brake booster and seal from the cowl.
Thread Starter
Instructor
Joined: May 2006
Posts: 194
Likes: 2
From: Worcester Mass
I have removed all the nuts from inside. Moving it around to release it from the push on nuts is just extremely hard. I've got one corner loose, trying to get the bottom loose now.
Thread Starter
Instructor
Joined: May 2006
Posts: 194
Likes: 2
From: Worcester Mass
Finally got the old one out and the new one in. Thanks for the tips Patches!
A few tips for anyone in the future:
- Use a 10mm or 12mm deep socket and 6 inch extension over the studs on the booster that hold the master cylinder on to give yourself some leverage to rock the booster side to side and free it from the push on nuts.
- You'll need a 1/4" drive 15mm deep socket and a 1/4" drive universal joint along with a few 6" long extensions.
- Wrap the universal joint in electrical tape when reinstalling the nuts to keep it from moving around too much.
- Put some poly bushing grease on the nuts to keep them in the socket when you reinstall them.
- Take out the drivers seat before you get started, much easier to work under the dash.
A few tips for anyone in the future:
- Use a 10mm or 12mm deep socket and 6 inch extension over the studs on the booster that hold the master cylinder on to give yourself some leverage to rock the booster side to side and free it from the push on nuts.
- You'll need a 1/4" drive 15mm deep socket and a 1/4" drive universal joint along with a few 6" long extensions.
- Wrap the universal joint in electrical tape when reinstalling the nuts to keep it from moving around too much.
- Put some poly bushing grease on the nuts to keep them in the socket when you reinstall them.
- Take out the drivers seat before you get started, much easier to work under the dash.
