Re: How to Replace your Brake Booster - Saab NG900 & OG9-3 Bulletin Board - Saabnet.com
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Re: How to Replace your Brake Booster
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Posted by Viggen Aero [Email] (#977) [Profile/Gallery] (more from Viggen Aero) on Tue, 3 Jul 2012 06:39:59 Share Post by Email
In Reply to: How to Replace your Brake Booster, Adam [Profile/Gallery] , Mon, 2 Jul 2012 17:03:58
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I just removed a booster from my 01 Viggen ( waiting for engine rebuild) to put in my 02 Viggen. Two removals and 1 install between Sun & Mon. I could have used your post a few days earlier LOL.

A few suggestions to your excellent write up- to allow more room to work:

- Move the fuse box out of the way- one 10mm plastic nut, push up to dislodge the spring clip holding to sheet metal. Disconnect the wire to the hood alarm switch.

- There is a horizontal bracket going from the firewall to the top left bracket that attaches to booster. Remove the bracket from the firewall (13 mm nut). Remove the 13 mm nut where this bracket attaches to booster. Move/ bend this bracket to get it out of your way (you can't remove it yet). Be careful it doesn't cut into any wires.

-Now you have access to the hard to reach lower left 13 mm nut. And the 2 nuts on the right side are easy to get to.

- Rather than disconnecting at the brake pedal- there is a spring clip in the rubber boot area. You remove that and the booster shaft separates from the shaft going to brake pedal.

-With manual trans- I also had to remove the line from the fluid reservoir to clutch.

-I couldn't get enough slack to pull the master cylinder out of the booster without disconnecting one brake line from the master. My brake pedal and clutch felt fine after- but I bled them anyway- they were due.

- The rubber boot is a real pain. I needed to save mine, because one was ripped. I was able to push it out of the way and hold it there with a small pair of vice grips.

- Don't forget to reattach the horizontal bracket.

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