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  1. #1
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    DIY Brake servo (booster) re-build with new o-rings and a new shaft seal

    For the following cars 533,535,m535,m5,633,635,m635,m6,735.

    This Do It Yourself (DIY) is to re-build the Brake Servo Booster #34331156925
    It includes a step by step procedure to repair the internal rubber seal and 5 o-rings.
    I just up dated this post DIY, I have added a new shaft seal and a how to replace the seal.

    Read the captions at the bottom of each photo.

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

    This repair needs to have the booster removed from the car.

    Tools needed: Dremal, vise, bench grinder, battery drill motor with reverse, 1-1/8 inch deep socket, 13mm 1/4 in drive socket with an extension into the drill motor, blade screw driver, 10mm drill bit or 3/8 inch metal drill bit, electric drill motor with 3/8 chuck.
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  2. #2
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    New update I found a supplier for the internal white teflon (2) high pressure o-rings

    Hi forum members,

    I located a supplier for the internal white teflon (2) piston rings. I should have them in about 15 days.

    I also found a supplier for the internal shaft seal at a lower price, 9.5mm I.D. This will take about 8 weeks to manufacture.

    Then I will have all of the interior replacement parts, a complete repair kit, for the brake servo/booster.

    Here is the photo link to the DIY re-build.

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

    Read the captions at the bottom of each photo.

    I also added a new helpfull hint for the re-build.
    Where the grub screw, screws into the booster cylinder there can be a burr created by the grub screw, on the interior. This burr can cut the 38mm O-ring, and also damage the 2 white high pressure teflon piston rings.
    Thanks to (tn).

    When I receive these new parts, I will revise the price.
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  3. #3
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    New-Updated DIY repair kit for the Brake Servo Booster

    Hi Forum Members,

    I now have all of the interior components for the complete re-build of the Brake Servo (booster). I have received the new teflon interior high pressure piston o-rings. I installed these new parts into my M6 over the weekend. The road test was a success, all of the parts work as they should!

    The new up-graded kit includes the 5 internal rubber o-rings, the 2 teflon piston o-rings, and a new shaft seal.

    I have also up-graded the Picasa Link, I took more photos and added more captions to show the correct method that I used in the assembly of the booster.

    The new price is $24.95 + shipping $1.95 USA, TOTAL $26.90 USD.

    International is also $24.95 + shipping $3.95 International TOTAL $28.90 USD.

    Here this the link to the DIY, step by step instruction, of the booster repair.

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

    I am also offering a QUICK FIX kit, this includes just the 38mm o-ring, and the shaft seal only. Price is $7.95 + $1.95 shipping USA TOTAL $9.90 USD.
    International is also $7.95 + $3.95 shipping International TOTAL $11.90 USD.
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  4. #4
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    MASTER6, Thanks for the write-up. It was easy to follow. You might think about posting it to the technical write up at Bigcoupe
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  5. #5
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    Hi JR,

    It is posted on BC, under the Tech section, and also the brake section.

    Thanks,

    Jay
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  6. #6
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    Hydraulic brake servo booster, 10 piece repair kit, and Rebuild Service

    Hi Forum Members,

    For the following BMW cars
    e28,533,535,m535,m5, part # 34331156925
    e24,633,635,m635,m6,L6, part # 34331156925
    e32,735 only. part # 34331156925

    e23,733,735,745 part # 34331152825

    This Do It Yourself (DIY) is to re-build the Brake Servo Booster, all of the 10 piece interior repair kit are identical, for both part numbers.

    I recently rebuilt another hydraulic brake servo booster, and I was amazed at how the rubber o-rings were deformed and hardened. They are now an oblong shape. The large o-ring 38.0mm x 3.0mm, at the front of the booster. It now measures 2.55mm high instead of 3mm. And is 3.28mm thick, were it should be again be 3.0mm. And it is noticeably more brittle. The smallest o-ring was brittle and it broke when removed.

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

    I am now offering to rebuild your booster for you, using my 10 piece repair kit.
    I am charging $85.00 + shipping back to you. Cont USA only. USD
    If you send me your address, and I can give you an accurate shipping quote, via FedEx Ground home delivery.
    Just send your booster to me, with a $ check. PayPal add 4%

    I also have a couple of spare rebuilt booster, that I can send to you. And you return your old core to me, shipping on you.
    Same price of $85.00 + ship + $60.00 core. USD
    PayPal add 4%
    [email protected]

    _________________
    Jay
    1987 M6
    https://picasaweb.google.com/1135658...X_js7i1IyIgAE#
    Booster rebuild
    https://picasaweb.google.com/1135658...nZ_Z7f6JrUyQE#
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  7. #7
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    Member No: 147218 WestCoast_89_635CSI is an unknown quantity at this point WestCoast_89_635CSI's Avatar
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    Great job on the step by step and pics. Not sure how much tension is on the bolt/plate rig you made to hold the spring. Rather than grind the housing I would try smaller bolts with nuts that just barely fit into the threaded holes so as to not ruin the threads. Could actually grind down a little of one end of the nuts and start threads on them to go in a mm or so. Haven't had to rebuild mine yet, great to know I can......thanks
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  8. #8
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    Looking for a better way

    Quote Originally Posted by WestCoast_89_635CSI View Post
    Great job on the step by step and pics. Not sure how much tension is on the bolt/plate rig you made to hold the spring. Rather than grind the housing I would try smaller bolts with nuts that just barely fit into the threaded holes so as to not ruin the threads. Could actually grind down a little of one end of the nuts and start threads on them to go in a mm or so. Haven't had to rebuild mine yet, great to know I can......thanks
    West Coast,

    Your idea has some merit, I think I will visit the hardware store, and see what I can come up with.

    Using a drill motor as per my method, should be retained, even with a smaller dia bolt.

    I have a spare booster I can play with.

    I think the trick will be to hold the nut from spinning, as you said. Might have to take a hex nut and grind off one side, so it won't spin, against the housing.
    Then follow up and use a tap to clean the threads.

    I will investigate and do an analysis. I will post to you the results.

    Thanks for your query, always thinking for a better mousetrap!

    Jay
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  9. #9
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    A lot of different ways to go, hex nut couplers, wing nuts might lock against the housing, I'm never excited about grinding a housing unless i really have to modify. I would also use a piece of tubing as a sleeve down the thread channel to protect them. Good luck, Rob
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  10. #10
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    Booster rebuild, new time saver tip from Rob

    Rob,

    I got your idea to work!

    I bought 2 - 1/4 - 20 x 5 inches long, round head with combo slot/phillips. 4 inch will also work.
    And 2 - wing nuts 1/4 - 20.
    and 2 - 1/4 -20 washers.
    Along with my old custom cross plate.
    I also added some white grease to the all thread.

    I had to use the bench grinder to grind down one side of each wing nut.

    The 1/4 - 20 all thread did not harm the boosters metric threads, but I still ran a tap to make sure.

    The booster I tried this on already had the sides ground down.
    I need to try this on a virgin booster.

    I took pictures with a new camera, but cannot my computer to read the new card, to down load.
    I will do it again tomorrow and use my old camera.

    Thank you, this is a big help.

    Jay
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  11. #11
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    Rob,

    I just updated my Picasa DIY brake servo booster thread, with new photos and captions.

    Thank you!!!!

    Jay
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  12. #12
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    Great help with thread!!

    To Rob,

    I was thinking of you this Christmas.

    Your idea that you passed on to me. It was a such a profound change in the way a booster could be repaired safely. Without having to grind down the sides of the booster!!!

    Thank you so much for your idea.

    Rob, If you ever need a booster repaired, call me. No charge!!!

    Thank you, best wishes for the holiday.

    Jay
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  13. #13
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    No problem Jay, that's what makes this board so great. Ways it could be done are many, depends what you have on hand, e.g. hydraulic press, maybe a drill press (put stem in chuck) by lowering the table as you take the bolts out, etc. Necessity the best invention as they say.
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  14. #14
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    Rob,

    A true bimmer enthusiast, and also a very humble guy.

    Thanks!
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  15. #15
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    Changes, 2-8-13

    DIY brake servo booster repair kit and rebuild service.

    Please read the captions under each photo.

    https://picasaweb.google.com/1135658...nZ_Z7f6JrUyQE#
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  16. #16
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    Special note! Please read! Some BAD boosters are being sold.

    Fellow 6er owners,


    Parts Geek and its supplier A-1 Cardone, are selling bad rebuilt hydraulic brake boosters.

    I had a client of mine who sent me a leaking booster. When I opened it up to repair, I noticed that it had an incorrect shaft seal installed.

    On top of that, the shaft seal was installed up-side down, and missing the garter spring.

    My client told me that his first Cardone from Parts Geek leaked as soon as it was installed, he sent it back to Parts Geek and they sent him another.

    When he installed the second one, it also leaked.
    And thats when he called me, and I used my rebuild service and sent him one of my rebuilt spares.

    When I received his core back, I set to rebuild it for the next client.
    I was shocked, the shaft seal was upside down, I then pressed the shaft seal out of the black plastic cup. The shaft seal specs are 9.5mm i.d. x 22.0mm o.d. and thickness of 6mm.
    The A-1 Cardone is 10.0mm i.d., way too big. It is made in China by YEI Shien, part #A19168 10x22x6.
    Because it was in backwards the garter spring came off, or was never there in the first place.
    I am going to also attach some photos, of the suspect seal front and back, and what a garter spring looks like.

    Here is my link, booster repair kit and rebuild service.

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

    Thank you,

    P4190001.JPGP4190003-001.JPGP4190004-001.JPG
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