FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Brake Servo


Brake servo, removing and installing
Special tools and workshop equipment required





^ 3320 Door adjusting wrench
^ T 10006 A Releasing tool

Removing
^ Remove cover, driver side.
^ Pull back and remove brake light switch and the brake pedal switch, if necessary.
^ Place sufficient lint-free cloths in plenum chamber in the area of the brake master cylinder.
^ Install bleeder hose and bleeder bottle to the front left brake caliper bleeder screw and open bleeder screw.
^ Operate brake pedal until sufficient amount of brake fluid has been pumped out for the brake fluid level in the brake fluid reservoir to sink below the supply hose.
^ Close front left bleeder screw.





^ Disconnect supply hose -1- from clutch master cylinder and seal with a plug.
^ Disconnect connector off float warning indicator sensor -2-.
^ Remove bolts -3-.
^ Remove brake fluid reservoir -4-. Press locking tab on reservoir downward and at the same time, pull brake fluid reservoir out of sealing plugs.





^ Disconnect brake lines -1- on brake master cylinder and seal brake lines and threaded holes with plugs from repair kit Part No. 1 HO 698 311 A.
^ Remove T45 torx head bolts -2 using special tool 3320 from brake servo unit.
^ Remove vacuum hose on brake servo unit.





^ First press brake pedal in direction of brake servo and hold.
^ Insert special tool T 10006 A and pull in direction of driver's seat. When doing this counter-hold brake pedal. (The pedal must not be allowed to move backward). This forces the mounting retaining lugs -3- off the ball head of the push rod -2-.
1 - Brake pedal
2- Push rod
3 - Retaining lugs

Note: For ease of illustration the separation of the brake pedal from the brake servo is shown with the pedal cluster removed.
^ Pull special tool T 10006 A and brake pedal together toward the driver's seat. (This forces the brake pedal off the ball head of the push rod).
^ Remove brake pedal from push rod.
^ Remove brake servo with brake master cylinder out of plenum chamber.

Installing
Installation is the reverse sequence of removal
Observe following points when installing:
Joining brake pedal to brake servo
^ Hold push rod ball head in front of mounting and push brake pedal in direction of brake servo until the ball head engage audibly.
^ After installing, bleed brakes.
^ Adjust brake light switch and brake pedal switch if necessary.