Removing the brake booster pushrod from the pedal assembly in a Volkswagen can be a challenging task. VW specifies a special tool for this procedure, often priced around $40. However, a cost-effective and equally effective DIY solution can be crafted using readily available materials. This article will guide you through creating and using a homemade Vw Brake Booster Removal Tool, simplifying this often-frustrating process.
Crafting Your Own VW Brake Booster Removal Tool
The core concept behind this tool is to replicate the function of the VW special tool: compressing the retaining clips that secure the brake booster pushrod to the pedal. This can be achieved using a piece of rectangular or round metal tubing.
One method involves using a section of rectangular steel tubing, approximately 1/2″ x 1″ with a 16 or 18 gauge thickness. Cut a 3″ length of this tubing and then make a lengthwise slot along one side. Alternatively, a piece of 3/4″ OD round tubing with a wall thickness of approximately 1/16″ can be used. A 2.5″ length is sufficient. Cut a slot along one side similar to the rectangular tubing version.
Regardless of the tubing type chosen, refine the tool by rounding both ends. This prevents damage to the plastic retaining clips and improves comfort during use. If using round tubing, you may need to slightly pinch one end of the tool in a vise. This narrows the tool’s contact point, allowing it to effectively engage the retaining clips. The slight narrowing, about 1/16″, ensures proper contact and efficient release of the pushrod.
Using the Tool
Before using the tool, applying a small amount of grease to the rounded end aids insertion and helps spread the retaining clips. Position the tool over the pushrod where it connects to the pedal, ensuring the slotted side faces the clips. Simultaneously press the tool firmly into the clips while pulling on the brake pedal. This combined action compresses the clips, releasing the pushrod.
Removing the Pedal
With the pushrod detached, removing the brake pedal requires creating clearance within the pedal box. Remove the five 13mm nuts securing the pedal box to the firewall. Four nuts are located around the brake pedal and booster, while the fifth is situated to the right of the accelerator pedal. Pulling the pedal box assembly away from the firewall provides enough space to maneuver the pedal. Finally, remove the pivot bolt at the top of the pedal. With a bit of careful maneuvering, the pedal can be extracted.
Conclusion
Removing the brake booster pushrod and pedal in a VW doesn’t necessitate the purchase of a specialized tool. By utilizing readily available materials and following these steps, a DIY VW brake booster removal tool can be easily fabricated. This cost-effective solution simplifies the process, allowing for successful removal of the pushrod and pedal. Remember to lubricate the tool and apply simultaneous pressure to the tool and pedal for effortless disengagement. This DIY approach saves money and empowers VW owners to tackle this task confidently.
