Brake Master Cylinder With Brake Servo From M.Y. 2002

Brake master cylinder with brake servo from m.y. 2002, removing and installing

Special tools and equipment





^ 3320 Door adjusting wrench
^ T 10006 A Releasing tool

Removing
^ Remove cover.
^ Pull back and remove brake light switch and the brake pedal switch if necessary.





^ 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 towards the driver's seat. (This forces the brake pedal off the ball head of the push rod).
^ Remove brake pedal from push rod.
^ Remove plenum chamber cover.
^ Remove water deflector.
^ Place sufficient lint-free cloths in plenum chamber in the area of the brake master cylinder.





^ Open brake fluid reservoir.





^ Extract brake fluid using VAS 5234 brake filler and bleeder unit.





^ Disconnect connector off float warning indicator sensor -1-.
^ Disconnect vacuum hose -2- on brake servo unit.





^ Remove trunnion bolt -1-.
^ Disconnect brake fluid reservoir and place to one side.





^ 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.
^ Loosen nuts -3- slightly. This makes separating the brake master cylinder from the brake servo easier.
^ Remove T 45 torx head bolts -2- using special tool 3320 from brake servo unit.
^ Remove brake servo with brake master cylinder out of plenum chamber.





^ Remove nuts -1- from brake master cylinder.
^ Carefully remove brake master cylinder out of brake servo unit.

Installing
Installation is in 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 engages audibly.
^ After installing, bleed brakes, Refer to Brake Bleeding, Service and Repair
^ Adjust brake light switch and brake pedal switch if necessary, Refer to Lighting and Horns, Brake Light Switch, Service and Repair