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Old 08-16-2010, 11:30 AM   #12
Keith Seymore
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Join Date: May 2009
Location: Motor City
Posts: 9,152
Re: Brake booster R&R

A final thought about the clip situation:

I put it back together yesterday with a "hairpin" style clip (like would be used on a hitch pin). I thought this was pretty clever -

I made a small installation tool using a piece of 1/2" wooden dowell rod (approx 4" long). By cutting a slot in the end I could insert the hairpin clip and the dowell would hold it. I could then come up from the forward side and insert the clip onto the brake pedal pin "longitudinally" from the front.

The only problem at that point was that the hairpin wouldn't open up enough to slip over the brake pedal pin, and I couldn't push it on. So....at that point I took a 1/4" piece of dowell and slipped it into the "throat" area of the hairpin. That opened the hairpin enough that it would start over the brake pedal and engage; the sacrificial piece of dowell just fell to the floor once the hairpin clicked into place.

I'm driving it around today to exercise the brakes and make sure the hairpin stays in place, but it was the only way I could think of to get any kind of clip back in there - plus - I'm pretty sure I can get it off fairly easily should I ever need another repair in that area.

So far, so good -

K
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