Brake servo replacement

[Uselesshippy]

hi have just replaced the brake servo as mine has been hissing for ages when you took your foot off the brake. Not a bad job can be done with hand tools, thought i'd break it down and post it though.

1/ remove the engine cross beam 3 bolts. You should disconnect the batt (i did'nt )

2/ remove the lower dash panel where the footwell light is, you might be tempted to leave it on, but trust me take it off, 2 torx screws only.

3/ unbolt the master cylinder 4 nuts and move it to one side carefully prying the piping out the clips.

4/ remove the rubber hose this was quite tight so it'll need a firm hand.

5/ undo the nut holding heat shield on and remove shield. Unclip the electrical connections. the servo should have nothing attached to it now in the engine bay.

6/ Now here's the uncomfy part, make sure the seat is as far back as possible, unclip the pin from the servo from the brake pedal pin, small flat blade screwdriver will do. gently move the brake pin to one side.

7/ undo the 4 nuts holding the servo to the bulkhead, you'll need deep sockets for this and a universal joint +long extension bars (12inch). And patience.

8/ once done the servo should be loose, move it to the right of the car as you look at it from the front, then insert a screwdriver through the pin hole as compress, this will allow the pin to come out through the bulk head.

9/ manipulate the servo upwards, with the pin pointing downwards and it'll come out fairly easy.

10/ to install just reverse this.

Things to watch for the brake lights may come on, the brake light switch just needed reseating.

Got my servo off a breaker from a 08 was exactly the same as my 03.

all in took me half a day, getting the 4 nuts off in the footwell took ages and lots of swearing, until i took the lower panel off, told you it's important. And could'nt work out how to manipulate the servo out until i worked out to compress the pin then it was quite quick.

tools required : set of metric spanners, set of deep metric sockets, extension bars + universal joint, screwdriver, torx keys or sockets,