Brake Booster Replacement

bobcowan · #1 (**permalink**) 10-13-2018, 06:16 PM

This job is a royal PITA. I'v been working on it most of the day, and now I'm stuck.

My brand new car has terrible brakes. The new brake booster is dead. I spoke with Perry Jackson at Iconic Parts (BDR), and he told me what booster to buy. It's a Porsche 944 part.

I got the new part yesterday, and it almost fits. The problem is that the pedal rod is about 2" too long. The old booster has a fully threaded rod, and it's been cut down.

But the new part doesn't have a fully threaded rod, so I can't really cut it down far enough to make it work.

I removed the old rod from the old booster, but I had to destroy the booster to do it.

I have some ideas, but I don't want to start cutting without asking for advice.

scottj · #2 (**permalink**) 10-13-2018, 07:22 PM

Do you have an ATE or a Girling booster? Here's the procedure: https://www.rjnunnally.com/how-to-fi...ter-to-an-e30/

bobcowan · #3 (**permalink**) 10-13-2018, 08:37 PM

Wow. That is perfect! I had a plan in my head that was a lot more complicated and time consuming. Thanx so much for saving me all that work.

I will do this tomorrow.

bobcowan · #4 (**permalink**) 10-15-2018, 08:25 PM

Done, done, and done. Thanx, Scott. Couldn't have done it without you. Well, I probably could have. But it would have taken me a week. The brakes are now working as intended. Maybe not as good as I would like. But as intended.

This job was a royal PITA. Threading and trimming the pedal rod was the easy part. Had to remove the side vent, steering shaft, and valve cover.

scottj · #5 (**permalink**) 10-16-2018, 07:41 AM

Glad it worked out Bob. I have to do the same thing on my brake and clutch masters for my pedal assembly. Of course. the Tilton rods are easily removed.