1984 XJ6: I am planning to install new Brake booster from SNG ... all the rebuild exchange offers came up zero stock.... did not want to wait for turn-around of my core.
Will put new seal kit in Master cylinder while out. Haynes manual says to remove master cylinder, booster and peddle box as an assembly, after sliding front seat back and removing front cushion. Just looking at bottom of peddle box with a mirror .... the foot-well seems to be getting smaller and smaller!!!

Question, has any one removed booster from peddle box with out removing peddle box assembly from car?
Thanks
David

 

I couldn't, and I looked long and hard for a way.
But I have a Series 2, so someone else with an S3 may have been able to do it.
(';')

 

Yes.

Don't try it.

Misery ensues.

Take a deep breath, remove the pedal box, and be done it it !

Cheers
DD

 

Agree with Doug and LnR. It seems difficult, but four bolts and out it comes as a unit.
On my XJS I thought it was possible, but amazingly the depression in the bodywork it sits in is just 3/4 of an inch too short, at the front of the servo (booster) to slip it forward off its fixing studs!

 

David, I agree with the others, remove the pedal box as a unit. I have a 1985 and there are 6 bolts, one larger than the other five. Don't forget to take the rubber pad off the pedal, won't come through the hole in the bulkhead if you don't.

Here is the part number for the one I bought, I didn't need to send them a core. I just checked Amazon and it is "no longer available". It's probably available from someone else.

Amazon $140 Cardone 53-5950 Reman Power Brake Booster.

Dave

 

Thank you all for expert advise... Good call Dave, on one bolt bigger and rubber pad needing to be removed.
As Doug said "take a deep breath and follow instructions." Tried to avoid pulling seat cushion, but gave up and pulled cushion; my elbow just kept getting in the way.
It is out and on the bench!!!!! The Good News is I did not break my wife's 6" vanity mirror, and She didn't have to call 911 to get me out.
I will post after is all back together.
Thanks & Rgds
David

 

Everything is off the bench and back in the car, not with out some drama!!! All that is left for tomorrow is brake bleeding.

Master cylinder reseal was routine. SNG booster was good and had all new hardware. This project require both Metric and SAE wrenches , both long and short, and sockets with several extension lengths.

The 6 bolts holding the brake box were corroded and although I replaced them with new, I did not clean brake box holes with a tap... big error, as it was very difficult to align and get bolts started upside down in a mirror with an arm that was too short. The one large bolt fell behind carpet side wall... requiring another removal ... The trim screws holding the carpet were so small, needing a 0 Philips, of course the only one I had, needed to be right where the brake peddle was. On removal of side carpet found an electrical ground point with several wires was corroded!! The stiffener plate under the brake box was corroded and required clean up and repaint.

Also had great difficulty getting brake line fittings back into the master cylinder, the lines had to be bent some what to get clear of MC on removal and no leverage to get them fitting straight in order to start. Finally unscrewed the other end and did MC first, then the three way fitting down below.
I will update after brake bleeding.

Thanks for advise and encouragement
Rgds
David

 

Yah, that sounds about right.

Dave

 

Well David, as they say, "if it's not one thing, it's another".
following your tribulations.
Ian.

 

Uh huh.....
I'll bet you're hoping this one lasts another 40 years.
I know that's what I'm hoping for mine!
(';')