Brake Master Cylinder With Brake Booster, Removing and Installing, (As of Model Year 2002)

Brake master cylinder with brake booster, removing and installing, (as of model year 2002)
- Remove driver side trim cover.
- Remove/pull back brake light switch and, if necessary, brake pedal switch.





- Press brake pedal in direction of brake booster and hold.
- Insert release tool T10006 A and pull in direction of driver seat. When doing this, counter hold on brake pedal. (At this moment the pedal must not be allowed to move backward). The mounting retaining lugs - 3 - will thereby be pressed off the ball plunger of the push rod - 2 -.
1 - Brake pedal
2 - Push rod
3 - Retaining lugs

Note: For ease of illustration separating the brake pedal from the brake booster is shown with the pedal cluster removed.

- Pull release tool T10006 A and brake pedal together toward the driver seat. (The brake pedal will thereby be pulled off the ball plunger of the push rod).
- Remove brake pedal from push rod
- Remove plenum chamber cover.
- Remove water deflector.
- Place lint-free cloths in plenum chamber in the area of the brake master cylinder.





- Open brake fluid reservoir - arrow -.





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





- Disconnect connection from the Brake Fluid Level Warning Switch F34 - 1 -.
- Disconnect vacuum hose - 2 - from brake booster.





- Remove dowel bolt - 1 -.
- Remove brake fluid reservoir and set aside.





- Disconnect brake lines - 1 - at brake master cylinder and plug brake lines with sealing plugs from repair kit Part No. 1H0 698 311 A.
- Loosen nuts - 3 - slightly, to simplify separating the brake master cylinder and brake booster at a later point.
- Remove bolts - 2 -, Torx socket head T45 with the door adjusting wrench 3320 from the brake booster.
- Remove brake booster with brake master cylinder from plenum chamber.





- Remove nuts - 1 - for the brake master cylinder.
- Carefully remove brake master cylinder from brake booster unit.

Installing
- Installation is in reverse order of removal.

Observe the following points when installing:

Joining brake pedal to brake booster
- Hold ball plunger of push rod in front of mounting and push brake pedal in direction of brake booster, so the ball plunger engages audibly.
- After installing, bleed the brakes.
- Adjust brake light switch, as well as brake pedal switch.