Capri - Brake Booster 2

Some weeks ago, I wrote about getting my brake booster repaired (see Post on 9 April).
Well, after a few very frustrating weeks, the car is back together and I have some good brakes with a good firm pedal.
Just let me explain what happened. I took the booster, some call it the brake servo unit to a firm that I have had many previous dealings with, and an owner who knows a great deal about classic cars. He indicated he could repair it.
After waiting over a week, I called & he said it was the most difficult unit he had ever tried to repair & couldn't get it just right. He promised to have it done soon. I then borrowed several other old units from one of the Capri Club members & took them over to the workshop to see if at least one could be salvaged.

Another week went by, and no booster but promises that it would be done by the weekend. Still no booster. I then rang to say that I was coming to collect them all when the owner indicated he had admitted defeat & had outsourced to another repairer. Two days later I had them all back, however two are in bits. Better than not having them at all. Very frustrating!This is how they look in bits.



This is the parts manual exploded view.

  

This is how the reconditioned unit looked & then back in the car.

 

It all went back together without too much drama but the biggest hassle was the pin that holds the clutch pedal in place. For some reason, there was very little clearance for it to fit in the groove, but after trying the plastic sleeve several different ways, I finally had it slide in.

The brake master cylinder fitted back on very easily and the pedal firmness is very good. No more hissing or fading pedal. I should have had it repaired long ago.
Now onto the next project - my white Capri is running like a hairy goat!

Capri - 2015 Auto Spectacular

The Auto Spectacular, held at Willowbank Raceway, west of Brisbane, is one event that always seems to attract a huge number of very different vehicles. There is something for all auto enthusiasts, from dragsters, motorcycles, new cars, vintage, classics to the usual Falcons and Holdens. Not many small Fords though!

The car display is the major feature, however the swap meet in the side paddock (very few Capri or Escort bits) combined with the many trade displays gives one plenty to look at. Then at 11 the drags start. Anyone can turn up & have a go and there were some interesting runners but no Capris this year.  So in all, there is a wide variety of attractions.

The club had four cars turn out .There were two other Capris on display, a silver V8 & the red V6 which was for sale. For the first time in many years, I didn’t have a car going to bring along. As usual, there is always someone wanting to talk about the Capris. We have a good spot at the venue – in the shade, beside the food stalls & dunnies, so in all, with the good weather, it was a worthwhile event to attend.

Here are some pics (click to enlarge).

Capri - Brake Booster Removal & Repair

In the last week I actually have been doing some work on my cars as there always seems something has to be fixed or improved. I was very reluctant to publish this post as, at first, I may have looked like a bit of a goose!
It actually relates to how you remove the brake booster.
I will detail how I have done it several times but on saying how painful it was, the guy at the brake specialists asked why didn't I  just undo the four nuts holding the booster to the bracket in the engine bay. I had never considered this but on discussing this method with other Capri owners, all considered this more difficult than the way I describe below. Undoing the nuts behind the bracket would also be quite difficult. If you have some thoughts on this, please let me know.

Removing the brake booster (by removing the four bolts inside the cabin)

Step  1: Remove the parcel shelf. Undo the screws keeping the top of the shelf in place, then the ashtray (2 nuts) & then the bottom nuts or screws holding the tray in place. Carefully pull the tray out trying not to catch it in any places.

Step 2: On the engine side, remove the vacuum hose from the top of the booster. (a few sprays of WD40 might help this process.)  Undo the two nuts holding the master cylinder to the brake booster. I did not disconnect the brake lines but just moved it all sideways & hooked it to the air cleaner brackets.

Step 3: Back inside the car & up under the dash are the four nuts holding on the booster. Three are really easy to undo but the one on the top left is a real bugger. In fact, it has to be located using torches & fingers. It was so difficult to get to that I eventually took the pin out of the clutch pedal & moved it slightly sideways so that I could get a spanner onto it. Once you can see it, it undoes fairly easily. The pictures show one of the nuts but I am not sure which one as taking the photos is also difficult.

Step 4: Back to the engine bay & then the booster with its bracket can be moved backwards & lifted out.

Step 5: Does one have to do all this or can the four bolts holding the bracket to the booster just be undone – all from the engine bay?

Wait until we put it back together.
I have taken to the brake specialists to work their magic but after nearly a week there, they claim to be having all sorts of dramas getting the booster to operate correctly. I hope I can get it back soon.

Postscript.
I haven't finished this project yet, as some two weeks later, I am still awaiting the return of my booster. Not happy! Hopefully this week & I will explain more.