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Frank's brakes weren't too crash hot even after swapping the front and brake mechanicals. So we had a look at the booster, which was the original, tiny diesel one.

B1 VW Passat brake booster conversion

 

Upon closer inspection, two things were clear. One - the master cylinder was completely shot. And two, the booster was filled with brake fluid.

B1 VW Passat brake booster conversion

 

Unbolt from inside the cabin as the rod protrudes through the firewall:

B1 VW Passat brake booster conversion

 

This is how much fluid came out of the booster. Not good.

B1 VW Passat brake booster conversion

 

At leas this is very accessible in Frank!

B1 VW Passat brake booster conversion

 

The replacement booster is from a 1996 Seat Cordoba and fits up perfectly. It only needs a little modification.

B1 VW Passat brake booster conversion

 

Remove the locking bracket from the old one, and the one from the new. You need the old one.

B1 VW Passat brake booster conversion

Enlarge the hole using a lathe.

 

See the ball? That needs to be gone.

B1 VW Passat brake booster conversion

 

All gone now!

B1 VW Passat brake booster conversion

 

Turn down the shaft and put a lovely VW thread on it.

B1 VW Passat brake booster conversion

 

And bolt the old bits back on.

B1 VW Passat brake booster conversion

 

And it all just slots back in!

B1 VW Passat brake booster conversion

 

We needed to replace a couple of brake lines so you need some line...

B1 VW Passat brake booster conversion

 

And a pipe bender...

B1 VW Passat brake booster conversion

 

Finally, plug the Cordoba master cylinder in and pop in the reservoir bottle. The bottle is too tall with the original sensor cap in place so we used a Mk 1 Golf cap. I might get a sensor reservoir from German Auto Parts later, they have a Mk 3 bottle with sensor that I think will fit.

B1 VW Passat brake booster conversion

 

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