Re: Brake Booster

[DJoh797014@aol.com]

Frank
Been there.  Done that.  With the brake booster.  I've
successfully rebuilt a few, but the rebuild only lasts
about 12 years.  

SS has rebuild kits but CAT lists them too.  They also
list a brake booster bypass bit.  This consists of two
unions and a short piece of flared brake pipe.  Bend it
in a 'U' and bypass the booster by connecting the input
and output brake pipes to the booster.  Bleed the brakes
and hit the road.  The brakes work but you have to push
hard on the pedal.  Other net members have been actively
discussing this topic.  Anyway the bypass will allow you
to leisurely rebuild the booster, powder coat the booster
tank etc.

Remember to keep everything sanitary.  Brake fluid is a
great paint remover.  If you get on your hands remember to
wash before touching any painted surface.

SK makes a small ciraclip pliers that will reach into the
booster bore to allow you to remove the ciraclip.  It was
the only make I found that worked.  Allow the others
including Craftsman were too big to reach far enough
into the bore.  You'll also need to make the small holding
tool described in the rebuild instructions.

Remember that the booster tank will be full of brake fluid.
Loosen the screws (dont remove) and crack open the end plate
The amount of fluid that will drain out is amazing.  Also amazing
is your wife's reaction to having the fluid spill onto her dining 
room table.  Yes indeed brake fluid is a great paint remover.
Also removes finishes from table tops too.

According to Tiger Tom all the Lucas rebuild kits after 1974 had
the wrong size foam rope in them.  The rope fits under the 
leather lip of the plunger and forces the leather out to make the
seal.  If the rope is too big the plunger will hang up.  He suggested
trimming the rope until the seal is good.  Above all make sure
the plunger is free to move in the tank.  Otherwise the first time
you put the brakes on they will goo on and not release.

My fingers are weary.  Have fun with the rebuild,  Follow the
instructions and you should be OK.  See you at SUNI III.
I'll be in the red MK IA with Illinois plates TIGERS.