Mark
I agree with Curt, et al
Its most likely your servo. If you send Curt some
money I am sure he will sell you a rebuild kit.
The Shop Manual has good notes on rebuilding
a servo. Go slow and keep everything clean.
I recommend not rebuilding it on the diningroom
table as brake fluid will take the finish off and
may cause the little woman to complain.
A few tips.
(1) When you have removed the booster, shake it.
Hear the brake fluid inside the vacuum canister?
This confirms the problem.
(2) Don't remove all the screws from the booster
tank at once. Leave a few loosely attached
as the spring loaded plunger inside may want
out badly.
(3) You probably will not be leaking fluid yet as the
gasket seals itself to plate. Find someplace
to catch the 3 or more cans a fluid that Curt
correct advises is inside the canister. The hood
of a nearby Chevy works. Use a screwdriver to
pry the plate back and it will be like a dam bursting.
(4) Once drained, remove the remaining screws but
be careful the plunger may come out with great
force. I mounted the booster in a vise and removed
the screws while holding the end plate.
(5) On final assembly, make sure the plunger moves
freely inside the can. If it sticks, the brakes will
stick on or off depending. Use the red rubber
grease to lube the inside. Lube the leather on the
plunger. It has to move smoothly.
Thats about it. Good Luck.
Dave Johnson, B382002668 (under repair) Aurora, IL
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