Relay 2.2 Hdi 2005 Brake Booster Removal

[slippets]

Hi, My first post

 

Trying in vain to remove my brake booster, looks simple, just 4 nuts under the dash and the pin on the brake pedal, will it come off, no.  Ive searched for Boxer booster removal and it mentions 2  clips on the side of the piston behind the pedal that need to be pressed in or removed.  Is this the case for the relay van, ive not recovered from mauling the booster with my jemmy bar yet to try again.  Many thanks

[paul.h]

Welcome to the forum.

 

A look at the citroen service box procedures only says to unclip the pedal, remove the pedal box and then the 4 nuts and the servo should remove. Maybe it has become stuck after a fluid leak which has softened the paint and then gone hard again acting like glue and possibly something like wd40 might free it off.

[coastline taxis]

I take it you mean the the servo unit ( laymans terms). Very very very rare these go wrong. 9 out of 10 its the vacum pump or a vacum leak. Any way to get it of _{you just got to push or pull like a train because they also glue it on to keep it water tight or the drivers floor would be soaking and there would be excess enginge noise}

[slippets]

Ok ongoing update, what a complete pain of a job, thanks for the advice of pedal removal revealing 4 extra nuts, so 8 in total. 4 on the pedal box and 4 below the pedal box hidden.  The booster is not glued in.  Problem 2 now is that with all nuts off there is not enough space to withdraw the booster from the bulkhead, the 4 pins on the booster are about 65mm long and they are about 45mm of space without lowereing or disassembling the engine, which i will not do.  I have resorted to removing the battery giving me side acces with a jigsaw, cutting off the bolts.  I think the top 2 bolts have room to come out, its just the bottom 2, 1 of which is hidden.  Im going to rotate the booster on its last pin and cut that too.  Then im going to have to cut an inch off the bottom 2 booster pins on the new booster to allow re-assembly,   I will tell you if it works ok!

[paul.h]

If the servo bolts (studs) are cut, will they still be long enough for the pedal bracket to fasten on or does it fasten to somewhere else ?

 

Citroen's procedures have nothing about cutting the bolts (studs) on the servo, only gives:

 

1. Removing

Remove the air cleaner .

 

Disconnect the vacuum pipe  from the servo.

Disconnect the wires from the brake fluid level indicator light.

Unclip the brake pipes from the bodyshell .

Remove the master cylinder mounting bolts .

Detach the master cylinder from the servo.

Remove the pedal bracket (see the relevant operation).

 

Remove :

• The servo nuts
• The brake servo

2. Refitting

Proceed in the reverse order to removal.

 

N.B. : Check the set back of the brake servo thrust rod.

Thrust rod set back with reference to support face : 0,1 mm to 0,3 mm.

Tighten the servo nuts to 20 Nm.

[coastline taxis]

if you look on the back of the servo where it marrys up to the bulkhead or on the bulkhead itself you will see what appears to be a foam pad. this is actually a glue pad and it will be on one side either servo or bulk head. the long studs are removed inwards by putting 2 nuts on and locking them together and unscrewing the studs out

[slippets]

Ok ive got the repacement booster back on after quite a bit of wedging, but now i need to lift the pedal box back up and re fit the 2 pins above the booster that hold the peddal box in position, however, the booster piston is fully out and i am unable to lift the pedal box past the piston.  I need to remove the steering rod to give it room to pass the piston.  I will do this in the morning,  Is it an easy job to remove the steering rod from the stereing wheel to the floor?  Thanks.