Clutch booster Rebuild

[KL570]

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

[KL570]

oh and this is the rebuild kit I used:

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

2 day delivery time!

cheers,
Kade

[MudRunnerTD]

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?

[KL570]

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!

[MudRunnerTD]

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!

[KL570]

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

[spektrum]

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.

[wildgu6]

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

[KL570]

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!

[KL570]

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