This video resolves a brake performance issue that can occur immediately following the replacement of the brake master cylinder on 1980, 1981, 1982, 1983, or 1984 USA built, Westmoreland, Mk1 Volkswagen Rabbits and Rabbit Pickups (aka: Caddy) that use the Bendix Brake Vacuum Booster. This does not apply to the German made cars that use the Ate system.
If your model has square headlights, it was built in the USA, at the plant in Westmoreland, PA. You master cylinder will have the wide "ears" where bolts to the brake booster. The master cylinder for the German car has a narrow mounting bolt spacing, a rubber o-ring on the back to seal against the booster, and a long metal cylinder that sticks out the back and goes into the booster.
There is a 1/4"(8mm) thick rubber spacer, located inside the Booster, that falls out into the bottom of the Booster, when the old brake master cylinder is slid off the Booster and Booster pushrod. This loss of the spacer is not visible while replacing the master. When the new master cylinder is installed, the missing spacer creates excessive travel in the Booster diaphragm, and pushrod, giving an extremely light, "no feedback" feel to the brake pedal, a hiss from the Booster, under the dash, and greatly reduced as well as, unstable, braking performance.
Removal of the Booster pushrod and the air seal from the Booster, and an inspection with a bright LED pen light, will show whether or not the spacer has fallen out of the cup that holds the base of the pushrod. If the spacer has fallen out, the Booster must be removed from the vehicle, the vacuum check valve grommet removed, the Booster turned upside down and shaken, and once the spacer is visible in the opening where the grommet was located, needle-nose pliers can be used to retrieve the spacer.
Put some grease on the back of the spacer, so that it's held into the cup, and won't be pulled out of position during re-assembly work.
Негізгі бет How To Replace The Brake Master Cylinder in a USA Built 1980-84 Mk1 Volkswagen Rabbit
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