Brake Servo Replacement

Brake Servo Replacement - UrS6 Brake Servo Replacement...

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UrS6 Brake Servo Replacement Douglas Fifield ( douglas.fifield@gmail.com ) July 2006 This write-up covers the replacement of the brake servo on a 95.5 S6. The master cylinder remained intact and connected, so there was no need to bleed the brakes upon completion. This can be done by one person, but having an assistant at the point of mounting the new servo might save time. There is a technical bulletin available on Scott Mockery’s site that discusses this and is viewable at: http://www.sjmautotechnik.com/trouble_shooting/brakeTSB47_92_2.html Tools: The job requires no special tools, but having the following helps: 1 13mm swivel socket with a ¼” drive 3 6” extensions, ¼” drive 1 ¼” ratchet handle Parts: 1 brake booster 441 612 101 B 1 foam gasket 431 612 193 4 M8 nyloc nuts N 011 184 9 Steps: 1. With the engine off, depressurize the bomb by pressing the brake pedal 20 to 30 times, or until it becomes rock hard. 2. The TSB on SJM’s site says to remove the battery ground strap. I did not. 3. Move driver’s seat as far back as it will go. 4. Remove the cover panel closest to the pedal cluster (2 screws, 10mm socket). 5. Remove the heavier knee bolster closer to the steering wheel (4 screws, 10mm socket).
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6. Remove air duct closest to pedal cluster. Held by one screw on one end and snaps into a clip on the other.
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7. Disconnect leads to light mounted in the duct. 8. Looking up at the brake pedal from underneath, you can see the servo pushrod coming through the firewall and the clevis where it attaches to the brake pedal arm. 9. There is some yellow sound insulation surrounding the rubber bellows on the servo pushrod that will have to be moved out of the way to access the locknuts
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that hold the servo in place. 10. Visible in the above picture, you can just see one of the nuts after the sound insulation was removed. Three of the four nuts can be seen and accessed relatively easily. The fourth nut is blind and must be accessed by feel. Give your back a rest and move around to the engine bay. 11. Note position of all the hard brake lines in the two multi-line clips that run along
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This document was uploaded on 04/15/2009.

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Brake Servo Replacement - UrS6 Brake Servo Replacement...

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