DIY brake booster re-build with new o-rings

For the following cars 533,535,m535,m5,633,635,m635,m6,735.

This Do It Yourself (DIY) is to re-build the Brake Servo Booster #34331156925
It includes a step by step procedure to repair the internal rubber seal and 5 o-rings.
I just up dated this post DIY, I have added a new shaft seal and a how to replace the seal.

Read the captions at the bottom of each photo.

https://picasaweb.google.com/1135658...nZ_Z7f6JrUyQE#

This repair needs to have the booster removed from the car.

Tools needed: Dremal, vise, bench grinder, battery drill motor with reverse, 1-1/8 inch deep socket, 13mm 1/4 in drive socket with an extension into the drill motor, blade screw driver, 10mm drill bit or 3/8 inch metal drill bit, electric drill motor with 3/8 chuck.

Hi forum members,

I located a supplier for the internal white teflon (2) piston rings. I should have them in about 15 days.

I also found a supplier for the internal shaft seal at a lower price, 9.5mm I.D. This will take about 8 weeks to manufacture.

Then I will have all of the interior replacement parts, a complete repair kit, for the brake servo/booster.

Here is the photo link to the DIY re-build.

https://picasaweb.google.com/1135658...nZ_Z7f6JrUyQE#

Read the captions at the bottom of each photo.

I also added a new helpfull hint for the re-build.
Where the grub screw, screws into the booster cylinder there can be a burr created by the grub screw, on the interior. This burr can cut the 38mm O-ring, and also damage the 2 white high pressure teflon piston rings.
Thanks to (tn).

When I receive these new parts, I will revise the price.

Hi Forum Members,

For the e28,e24,e32. 533,535,m535,m5,633,635,m635,m6,735 only

I now have all of the interior components for the complete re-build of the Brake Servo (booster). I have received the new teflon interior high pressure piston o-rings. I installed these new parts into my M6 over the weekend. The road test was a success, all of the parts work as they should!

The new up-graded kit includes the 5 internal rubber o-rings, the 2 teflon piston o-rings, and a new shaft seal.

I have also up-graded the Picasa Link, I took more photos and added more captions to show the correct method that I used in the assembly of the booster.

The new price is $24.95 + shipping $1.95 USA, TOTAL $26.90 USD.

International is also $24.95 + shipping $3.95 International TOTAL $28.90 USD.

Here this the link below to the DIY, step by step instruction, of the booster repair.

https://picasaweb.google.com/1135658...nZ_Z7f6JrUyQE#

I am also offering a QUICK FIX kit, this includes just the 38mm o-ring, and the shaft seal only.
Price is $7.95 + $1.95 shipping USA TOTAL $9.90 USD.
International is also $7.95 + $3.95 shipping International TOTAL $11.90 USD.

Dremal hobby tool at Home Depot $69.00 this is a must have tool to do this job correctly!
http://www.homedepot.com/h_d1/N-5yc1...&storeId=10051

Hi Forum Members,

For cars, e24,633,635,m635,m6,L6, e28,533,535,m535,m5, e32,735 only, e23,733,735,745.
For part # 34331156925 and e23 part # 34331152825, both part numbers share all of the 10 piece repair kit, they are identical.

I recently rebuilt another hydraulic brake servo booster, and I was amazed at how the rubber o-rings were deformed. They are now an oblong shape. The large o-ring 38.0mm x 3.0mm, at the front of the booster. It now measures 2.55mm high instead of 3mm. And is 3.28mm thick, were it should be again be 3.0mm. And it is noticeably more brittle. The smallest o-ring was brittle and it broke when removed.

https://picasaweb.google.com/1135658...nZ_Z7f6JrUyQE#

I am now offering to rebuild your booster for you, using my 10 piece repair kit.
I am going to charge $85.00 + shipping back to you. Cont USA only. USD
If you send me your address I can give an accurate shipping quote.
Just send your booster to me, with a $ check. PayPal add 4%

I also have one spare rebuilt booster, that I can send to you. And you return your old core to me, shipping on you.
Same price of $85.00 + ship + $60.00 core. USD
PayPal add 4%

Looks like you've put together a nice kit. Some very good info here.

Hi Forum Members,

For the following cars, that have a Hydraulic brake servo booster.

e28,533,535,m535,m5;
e24,633,635,m635,m6,L6;
e32,735,750;
e23,728,730,733,735,745;

This Do It Yourself (DIY) is to re-build the Brake Servo Booster #34331156925.
On the e23 it is part # 34331152825
The e23,e24,e28,e32 735 all of the 10 piece interior repair kit are identical., for both part numbers.

The e32 750 has a different part # 34331161772,
It uses a shaft seal instead of an o-ring at the firewall end. And is slightly more expensive.

I recently rebuilt another hydraulic brake servo booster, and I was amazed at how the rubber o-rings were deformed.
They are now an oblong shape. The large o-ring 38.0mm x 3.0mm, at the front of the booster. It now measures 2.55mm high instead of 3mm.
And is 3.28mm thick, were it should be again be 3.0mm. And it is noticeably more brittle. The smallest o-ring was brittle and it broke when removed.

https://picasaweb.google.com/1135658...nZ_Z7f6JrUyQE#

REPAIR SERVICE

I am now offering to rebuild your booster for you, using my 10 piece repair kit.
For the e23,e24,e28,e32(735).
The price is $85.00 + shipping back to you. Cont USA only, USD.
If you send me your address, I can give an accurate shipping quote.
Via FedEx Ground home delivery with tracking.
And I will send you my address.
Just send your booster to me, with a $ check.
Insure for $175.00
PayPal add 4%.

I can also rebuild your e32 750 booster for $95.00 + shipping back to you.
Cont USA only, USD. Insure for $220.00
PayPal add 4%

REBUILD WITH CORE

I also have a couple of spare rebuilt boosters, and I can send one to you.
For the e23,e24,e28,e32(735).
And you return your old core to me, shipping on you.
Insure for $175.00
Same price of $85.00 + ship + $60.00 core. Cont USA only, USD.
Core charge refunded via PayPal.
PayPal add 4%

I also have a spare e32 750 booster that I can send to you,
for $95.00 + ship + $95.00 core.
Cont USA only, USD.
Core charge will be refunded via PayPal.
Insure for $220.00
PayPal add 4%

Send me an e-mail to get started jay_c_stratton@hotmail.com

I have made some recent changes in the DIY repair kit and rebuild service, as of 2-8-13.
Please refer to my DIY link.

https://picasaweb.google.com/1135658...nZ_Z7f6JrUyQE#

Hello e28 owners,

Parts Geek and its supplier A-1 Cardone, are selling bad rebuilt hydraulic brake boosters.

I had a client of mine who sent me a leaking booster. When I opened it up to repair, I noticed that it had an incorrect shaft seal installed.

On top of that, the shaft seal was installed up-side down, and missing the garter spring.

My client told me that his first Cardone from Parts Geek leaked as soon as it was installed, he sent it back to Parts Geek and they sent him another.

When he installed the second one, it also leaked.
And thats when he called me, and I used my rebuild service and sent him one of my rebuilt spares.

When I received his core back, I set to rebuild it for the next client.
I was shocked, the shaft seal was upside down, I then pressed the shaft seal out of the black plastic cup. The shaft seal specs are 9.5mm i.d. x 22.0mm o.d. and thickness of 6mm.
The A-1 Cardone is 10.0mm i.d., way too big. It is made in China by YEI Shien, part #A19168 10x22x6.
Because it was in backwards the garter spring came off, or was never there in the first place.
I am going to also attach some photos, of the suspect seal front and back, and what a garter spring looks like.

Here is my link, booster repair kit and rebuild service.

https://picasaweb.google.com/1135658...nZ_Z7f6JrUyQE#

Thank you,

Keep up the good work!