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Thread: Clutch booster Rebuild

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    Clutch booster Rebuild

    alright guys here's the rebuild I did on my clutch booster. cost me less than 100 and works as good as new!

    step 1:

    remove everything off front of booster and undo everything inside the firewall that is connected to the booster. should be 4 nuts holding it in place.

    here's what you get:
    ImageUploadedByTapatalk1355795203.038106.jpg

    1 stuffed booster

    step 2: put booster into vice and clamp it with the 4 studs Inside and the main shaft pointing DOWN. don't squeeze the crap out of it, just enough to hold it in place and not move.

    ImageUploadedByTapatalk1355795433.358818.jpg

    here's the fun part...

    step 3: get a piece of square bar about 400-500mm long. drill 2 holes in it to slip over 2 diagonal opposing studs, make sure you've removed the little rubber seal and washer with a screwdriver and remove the shaft that goes into the master cylinder.

    ImageUploadedByTapatalk1355795603.288255.jpg

    now use it as a massive breaker bar ad PUSH!!! will take a bit of muscle!! you need to rotate the top half until the little gaps line up and you can seperate the 2. THE 2 HALVES ARE SPRING LOADED. TAKE CARE SEPERATING!

    here's what you get
    ImageUploadedByTapatalk1355795806.056030.jpg
    ImageUploadedByTapatalk1355795845.423955.jpg

    pretty much, from here just replace all the corresponding parts.

    make sure everything is clean before you out it back together, and paint the outside if you wish!

    here's some more pics if they help!

    ImageUploadedByTapatalk1355795969.873575.jpg

    ImageUploadedByTapatalk1355796055.323502.jpg

    ImageUploadedByTapatalk1355796118.802920.jpg

    ImageUploadedByTapatalk1355796145.374138.jpg

    ImageUploadedByTapatalk1355796173.990084.jpg

    and finished!!

    ImageUploadedByTapatalk1355796196.788678.jpg

    any questions feel free to ask! I'll try an remember what I did haha

    cheers,
    Kade

  2. The Following 15 Users Say Thank You to KL570 For This Useful Post:

    amm009uk (13th June 2014), Bloodyaussie (2nd July 2014), Bob (18th December 2012), dom14 (18th August 2016), gazman63 (15th February 2023), GQSWB4.2 (17th November 2014), jedediah (4th March 2015), mudnut (2nd July 2014), MudRunnerTD (18th December 2012), nissannewby (18th December 2012), Robo (21st December 2012), spektrum (18th December 2012), Teeny (13th May 2013), timmay556 (23rd June 2014), weinie (20th June 2017)

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  4. #2
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    oh and this is the rebuild kit I used:

    http://www.atocauto.com.au/proddetai...od=30684_01J25

    2 day delivery time!

    cheers,
    Kade

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    mudski (18th December 2012), Robo (21st December 2012), Teeny (1st July 2013)

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    Moderator MudRunnerTD's Avatar
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    Outstanding work there bloke. I probably would have just chased a second hand one but your the man!! Nice one!

    Would the Brake Booster be the same task? must be very similar?
    Its a Nissan! =====> Its a Keeper!! ....... Got a TD42 in it BONUS!! ....... I'm a lucky bugger! I've got 2 of em!
    Check out my Toy --> MudRunnerTD's GQ From the Ground Up

    Quote Originally Posted by Rogue Dung Beetle View Post
    Wish it was Nissan though, Toyotas just can't keep up with the Pootrol pace.
    The only good thing about an 80 series is..... the front end?? Wrong!!, the Engine?? Wrong!! the Full Time 4WD system?? Wrong!! Its the NissanPatrol.com.au stubby holder fitted over the transfer lever.
    WARNING: Towballs used for recoveries can, and do kill people and damage property.

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    cheers mate!

    yeah I got quoted 250, reasonable, but I was a poor student at the time Nd I freakin love doing stuff myself. learn more about stuff and how to properly diagnose problems this way

    brake booster is exactly the same! just a bigger diaphragm really!

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    Moderator MudRunnerTD's Avatar
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    Quote Originally Posted by KL570 View Post
    oh and this is the rebuild kit I used:

    http://www.atocauto.com.au/proddetai...od=30684_01J25

    2 day delivery time!

    cheers,
    Kade

    Great Store too mate! Nice find!
    Its a Nissan! =====> Its a Keeper!! ....... Got a TD42 in it BONUS!! ....... I'm a lucky bugger! I've got 2 of em!
    Check out my Toy --> MudRunnerTD's GQ From the Ground Up

    Quote Originally Posted by Rogue Dung Beetle View Post
    Wish it was Nissan though, Toyotas just can't keep up with the Pootrol pace.
    The only good thing about an 80 series is..... the front end?? Wrong!!, the Engine?? Wrong!! the Full Time 4WD system?? Wrong!! Its the NissanPatrol.com.au stubby holder fitted over the transfer lever.
    WARNING: Towballs used for recoveries can, and do kill people and damage property.

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    thanks mate! was actually recommended by someone on this forum ages ago!

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    Good job.

    My clutch booster has completely stopped working now. The brake booster is intermittent too, although could just be a lack of vacuum from the clutch booster leaks.
    -------------------------------
    1992 Patrol GQ LWB TD42

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    Patrol God wildgu6's Avatar
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    Great write up Kade and pics to match.
    Very understandable for a DIY.
    Great work mate, cheers


    TAP TAP TAP MERRY XMAS TO ALL AND A SAFE NEW YEAR TO COME
    "Tonka Tuff" 08-GU6, 3.0lt crd, 5 Speed, Turbo Diesel, Hpd, Arb, Ome, MT Baja Atz.

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    Quote Originally Posted by spektrum View Post
    Good job.

    My clutch booster has completely stopped working now. The brake booster is intermittent too, although could just be a lack of vacuum from the clutch booster leaks.
    if they're both not working and you're not losing fluid I'd be checking your vacuum pressure man. probs a leak somewhere!

  13. #10
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    Quote Originally Posted by wild98 View Post
    Great write up Kade and pics to match.
    Very understandable for a DIY.
    Great work mate, cheers


    TAP TAP TAP MERRY XMAS TO ALL AND A SAFE NEW YEAR TO COME
    cheers bud

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