R50/R53 :: Hatch Talk (2002-2006) Cooper (R50) and Cooper S (R53) hatchback discussion.

R50/53 How FXXX does the brake booster come out !!!!!!

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Old Apr 6, 2023 | 01:39 PM
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From: OakCreek
How FXXX does the brake booster come out !!!!!!

Followed procedures to a T. I even loosened the 2x bolts on the rear header panel so it can bend up , fusebos loosened and out of the way along with the aorbox ecu ect ,I've bent vacuum lines as much as they can be without breaking , I've loosened the brake line in the wheel well for more slack.. NOTHING. it WILL NOT come out.. what am I doing wrong ?

 
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Old Apr 6, 2023 | 02:10 PM
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Ok I finally got it. I had to pull it towards the front of the car and down towards driver side wheel well and use all the force I could with my little 150lb frame..lol it's out , it's fricken out ! Buuuut now , what's the trick to get the new one back in ? Is there a way to predepress the brake plunger or something,??



 
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Old Apr 10, 2023 | 03:23 PM
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So trick is :
remove airbox , loosen fusebox as well as maim wire harness, unbolt the header panel with 1x bolt on either side and on the right side wedge something in there to get about 3-4in extra clearance, bend the brakelines put so they are wedged and held infront of the strut tower , remove the brakeline in drivers side wheelwell so you can move the line up and towards the front of the car infront of the brake booster.
remove master and bolts inside footwell and the clip on the brake pedal along with the retainer bolt thingy.
then while pulling the brake boost with 2x hands , one at 3 o'clock and other and 7 o'clock , rotate it counterclockwise and get the tip lip to clear the header panel and then pull the bottom lip up over the mounting area above the transition/below the airbox stuff..
Reinstall goes the exact opposite and make sure the plunger lines up into the brake pedal correctly. I found having the brake pedal depressed with something made it MUCH easier to get it lined up correctly. If you don't the booster doesn't need to be fully removed , only a few in enough to clear the pedal and try to reseat it correctly.
NOW THE ***** PART ! you NEED a power bleeder. I ended up bleeding the brakes probably a total of 20x times and my pedal still sunk to the floor..I HAD to bleed it , drive the car hard on the brakes for a few blocks and repeat the process. Then , only then I finally got the brake pedal to NOT sink to the floor whole at a stop. I may have to bleed it one more time because I feel engagement is alittle low but atleast my calipers no longer hangup up and my pedal doesn't sink to the floor..it stops normally again.. what a pita that was.. I thiiiiiink driving it inbeween bleedings pushed the trapped air out because the powerbleeder may not have been strong enough though I did put it upto 17psi..







 
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