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Hello everybody,
My 9-5 is out in the garage on ramps midway through the brake booster replacement job. I elected to use the method where you remove the booster and it's bracket, which requires removing the windshield wipers, removing 2 bolts from underneath, etc.
So I've gotten the bracket unbolted, everything moved out of the way as best as I can without opening any brake lines, and now I'm stuck. All the directions refer to removing a rectangular locking washer from the rod between the brake pedal and the booster. The Haynes manual says to remove a similar washer from the pin which connects this rod to the brake pedal itself (this is done inside the car). I've taken that one out and so now the brake pedal is disconnected.
Two questions - do I remove the other locking washer, which is in the engine compartment, on a rusted looking piece which seems to screw onto the booster? It's the one in the middle of this picture. The "Frans Swaalf" directions state:
"Push up the rectangular locking spring washer (circlip-like) that secures the push rod to the brake pedal to the receiving hollow rod from the brake booster.
This washer is reachable (with a small hand) from the right hand side of the brake booster. Take care, it will jump out!"
This isn't entirely clear to me. It's not obvious what removing that washer would actually do anyway.
Whatever the case with the washer, my next question is, how the heck am I supposed to maneuver this thing out? It seems quite impossible that it's going to fit out either 1) towards the front of the car, underneath the black-clad rigid brake line, or 2) straight up, between that same brake line and the frame to the rear. I've removed the battery, fuse box, hood switch, and moved the little fuse box or whatever it is towards the center of the car on the frame (same one you move when replacing the coolant BPV). I'll post a few more pictures.
I fortunately have time to deal with this but of course would rather get it resolved sooner than later. Thanks for any help!
jeff
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