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  1. #1
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    BRAKE BOOSTER REBUILD HELP

    I had a brake fluid leak on my new (to me) 86 635 and I followed the terrific article in Norm Grills website about how to do it (big coupe group).I thought I followed it to a Tee.
    I refilled the brake fluid reservoir and the PS fluid reservoir with tranny fluid.Cleaned it all up and pumped the brake pedal and got no resistance after 20 pumps or so.Heard screeching sound and found my
    brake fluid reservoir was empty.Filled it again and started pumping, same thing.I have a slight leak at the rectangular hole at the bottom of the booster but not bad enough to drain the 2 qts of tranny fluid that I have lost.As I now have a toxic puddle of kitty litter and trans fluid on my garage floor I need to call for help.

    1. I got a new 3x38 mm O ring and installed it correctly, why is it leaking?
    2. Brake fluid connections are not cross threaded, I "worried" them in by hand and then tightened them with a wrench.
    3. Where's all the tranny fluid going, there's only a rubber hose and a fitting that I tightened OK.

    I can't get underneath until the sludge dries out, should I dismantle everything again, my brake fluid level hasn't changed.I just get a sqeaking sound but no back pressure at all when I pump the pedal.

    Where did I go wrong?

    I'll remember somebody in my will!

    Jim C


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    Tranny Fluid in your brake system?

    Unless I'm reading your posting incorrectly, your 2nd paragraph states you filled your brake reservoir with tranny fluid. It should be brake fluid DOT4. Power Steering reservoir should be Dexron IV (current version). I'm not sure how you would adequately purge or clean out your brake system.

    No need to include me in your will ;)

    Joe
    84 633CSi 165k Polaris


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    Re: Tranny Fluid in your brake system?

    Pardon me, you are correct.

    I did put the fluids in correctly.
    Tranny fluid in brake reservoir
    DOT 4 in brake system.

    I can't figure out why I have no brake pedal pressure and where all the PS fluid is going

  4. #4
    Ray7er6ers5er3er
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    Are U pumping the brakes while car is running?

    Should be done while off. The Pwr steering also gets it's fluid from there so while running...turn the sterring wheel from full left to full right a few times...shut off engine and repump brakes til hard. If it doesn't get hard, check the brake bomb (hydro accumulator). Just my o2

    Ray

  5. #5
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    booster update

    I pumped the brakes while the car was off.

    Maybe I'm wrong, if so someone correct me.

    I think my 2 qts of PS fluid went to the brake booster and then because I didn't somehow correctly install the O ring.It looks like the O ring keeps the PS and brake fluid seperate so now I'm pumping PS fluid into the brake system.

  6. #6
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    Breech?

    If there's a mixing of fluids, first check the appearance of your brake fluid in the brake fluid reservoir and if you still think there's a cross-over, bleed your brakes.

    Can't tell you where 2 qts could have migrated.Joe
    84 633CSi 165k Polaris


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    have a look at this site ....maybe it will help

    and cover something you missed.


    brake booser o ring fix

  8. #8
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    Re: have a look at this site ....maybe it will help

    Wonderful writeup and visual aids also!.

    Update, I had dropped the 4" rod in the kitty litter covering my floor and didn't hear it hit.I had put the brake MC on the brake booster without it.Put it back in but may have switched the ends on it.

    Put that back in, bled the brakes and all was well till this morning when I saw a big puddle of my Dot 4 on the floor. Reservoir was still full.The excellent article showed PS fluid leaking because of the O ring, I was previously and still am leaking brake fluid.

    I'm confused.
    Jim

  9. #9
    Regal6er
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    WHAT ARE THE SYMPTOMS OF A FAILED BRAKE BOOSTER?


  10. #10
    Ed O'Reilly
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    Re: BRAKE BOOSTER REBUILD HELP

    Could be the shaft seal too. Can't buy as it is an odd size 9.5 mm. Most likley done to keep us from doing exactly what we are doing

  11. #11
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    DS Training

    Quote Originally Posted by Ed O'Reilly View Post
    Could be the shaft seal too. Can't buy as it is an odd size 9.5 mm. Most likley done to keep us from doing exactly what we are doing
    get back to work and complete your training

    signed
    IS Dept
    Reply With Quote Reply With Quote 155.94.70.222

  12. #12
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    Did you get this problem resolved? Just wondering how this turned out, since I plan on doing this same job to my car soon.
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    BMW Hydraulic brake servo booster repair kit and rebuild service

    Hello forum members,

    I have a booster repair kit and a rebuild service

    This is my link, please read the captions at the bottom of each photo.

    https://picasaweb.google.com/1135658...nZ_Z7f6JrUyQE#

    PICT0001.jpg
    Reply With Quote Reply With Quote 72.130.2.5

  14. #14
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    wow this is great!

    Quote Originally Posted by master6 View Post
    Hello forum members,

    I have a booster repair kit and a rebuild service

    This is my link, please read the captions at the bottom of each photo.

    https://picasaweb.google.com/1135658...nZ_Z7f6JrUyQE#

    Attachment 6310
    I bookmarked this. You can't find information this thorough anywhere. Kudos for you. thanks!
    Reply With Quote Reply With Quote 108.45.106.158

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