Viggen Brake Booster Plunger Seal - Saab NG900 & OG9-3 Bulletin Board - Saabnet.com
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Viggen Brake Booster Plunger Seal
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Posted by Justin VanAbrahams [Email] (#32) [Profile/Gallery] (more from Justin VanAbrahams) on Wed, 30 Aug 2017 12:52:42 Share Post by Email
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I have a 2002 Viggen that had a hiss from the brake booster that went away when pressing the pedal. Seemed indicative of a failure of the plunger seal.

After some research, I found that Uro/ARA #228477016 and #0014300708S (same part) are designed to work in ATE power boosters in Mercedes and Volvos that are similar to the one in the Viggen, maybe other Y2K Saabs (9-3, 9-5). The seal runs about $30, which is cheaper than a lot of other options so I ordered one from eeuroparts - you need to search by part number as they do not have this seal listed under any applications yet.

I watched this video:

https://vimeo.com/210329449

more than once, then got to work.

The seal that came out of my booster was missing a pretty substantial chunk of the side, much larger than I would have guessed given the slight hissing. But, it was a pretty clear indicator the plunger was indeed leaking.



Getting it out was easy. I just yanked with my fingers.



Original vs replacement seal, for reference:



Getting it back in was no bueno, a total disaster. I got the edge of the seal in without issue, but could not get even the first rib past the booster body. Every attempt resulted in the same thing, the installation tool sliding inside the seal rather than forcing it down. I tried with a hammer like they suggested and even a press... same thing every time. I tried for hours, it was very frustrating.

Eventually, the rubber of the first rib started ripping away so I stopped and ordered two more $30 seals to try again... I figured even at $100 it was cheaper than other options, and worth giving it another shot or two.

Second attempt was successful, though I am pretty convinced there is no way to install it as demonstrated in the Uro video. Instead, I compressed the plunger in a press; once compressed the booster plunger can rock around a bit makes all the difference. With the plunger compressed an inch or so I was able to mostly install the seal by hand, working it in as I moved the plunger around. A little finish work with the driver and it was done.



It's possible the specified installation method doesn't work because it's not quite the right seal - I don't have a Mercedes or Volvo booster available for comparison. But, it does fit well and seems to create an acceptable seal. Not sure it's perfect or that it will last, but by the same token I don't have any reason to believe it won't.
I guess we'll see how long it lasts!

posted by 12.195.130...

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