Replacing T25 Servo

[paul66beetle]

Any hints & tips. So far struggling. Access is dire, Haynes book of lies is not much help.

Those two bars attached to steering seem in the way but bolted with shear bolts.

Anyone replaced a servo give me some help?

[pirate-pete]

I drilled the heads of the shear bolts out as I could not get a decent grip with my mole grips. In hindsight I should have tried tapping it round with a chisel. One came out easily but the other was a pain as the drilled out stub then sheared off when I tried to remove it. Had to completely drill it out once the arm off the van. You will need the bars out as well as the dash panel.

I just lowered the steering column down onto the seat rather than removing it or the wheel as the Haynes suggests. Once steering column out of the way undo the clutch master cylinder from the pedal bracket and the pedal bracket from the bulkhead . Then its a case of jiggling the pedal bracket and servo assembly out through the gap in the bodywork. Easier said than done unless you pick the right angle first time.

As for replacement I couldn't see how I was going to get the clutch pedal clevis attached to the master cylinder pushrod with the cylinder still piped in so I removed the cylinder. That bit easy enough but when I came to bleed it I found the bleed nipple had been previously sheared off at the slave cylinder so had to replace that and a bit of pipe leading to it from the rear flexy.

Putting the dash together straightforward but I used normal bolts rather than sheer ones to hold the column on.

[paul66beetle]

Well before I read the above I went back and got the shear bolts off with mole grips. Left the dash on so the whole lot wouldn't come out but it came up enough so I could get to the back to undo the servo from the pedal assembly. What a royal pain getting access back there.

I will replace the shear bolts with some Allen key bolts.

Any tips on adjusting the servo clevis? Does it need adjusting at all? I noticed a lock bolt.

I stripped the pedal assembly and lubricated the whole lot before sticking back together.

I still have to put it all back!

I am replacing the mastercylinder too as it was seeping through the tiny hole by the servo.

[pirate-pete]

Well done for getting the servo off with the dash in place. I wanted the dash off to do other jobs like heater fan repair but didn't think I would have got to those nuts at the back with the dash on if I'd just wanted to swap the servo.

For the clevis adjustment the specs say 111.5mm from the flat face on the servo with the four studs sticking out to the centre of the hole for the clevis pin. I measured the old one with a steel rule and it was exact to as near as my eyes can see lining it up as best I could as you can't get the rule next to the clevis. The new (well secondhand) one was about 5mm out so I adjusted it to 111.5 give or take a mil or so.

Getting it back should be OK as your pedal box is still in place. The hard bit was connecting the clutch clevis to the pedal as I could not get my fingers in to fit the pin. On the way out I left the clutch cylinder pushrod stay attached to the pedal but I could not line it up to put it back that way either hence the reason I disconnected the hydraulic pipe from the clutch master cylinder. As you'll be replacing all the brake fluid it makes sense to flush out the clutch system with new fluid too.

[paul66beetle]

I did the same thing when removing the pedal assembly, slid the pushrod out while attached to clutch pedal. The rod is looking very corroded and rusty I dread to think what the clutch master cylinder is like. I am replacing the brake master and am tempted to replace the clutch one too while I am at it. I have already done the slave previously.

I have assembled the pedals, but not fitted yet. So I may have the same problem getting the pushrod back.

I cleaned out the brake resevoir while I was at it. It was a bit grotty.

Thanks for the help.

[paul66beetle]

[paul66beetle]

Well thats the Brake Master cylinder and reservoir cleaned up!

The clevis pin has been adjusted by eye, although doesn't quite match up with the pedal? Is this intentional? Should I have to press the pedal a bit to line then up?

I did think a brake pedal stop was missing but after a lot of digging they only put them on the clutch pedal even though there is a hole for one on the casting. (confusing)

http://shufti.wordpress.com/2011/02/01/ ... ore-flush/" onclick="window.open(this.href);return false;
http://www.thesamba.com/vw/forum/viewtopic.php?t=401822" onclick="window.open(this.href);return false;

[pirate-pete]

Sounds like how mine was.

When reassembling I noticed the rubber stop missing from one side too. I had an identical one in my spare box that would have most likely come off a 70's Ford or Vauxhall so I tried fitting it. Once the clevis pin was in place I noticed the pedal arm would no longer touch the frame here so I too must have pushed the pedal in slightly to get the clevis to line up. As it is the servo rod length stopping the pedal coming back far enough to hit the bracket, the rubber stop is not needed so I removed it.

[paul66beetle]

Just ordered up a new clutch master cylinder, the old one worked but looks original and while I am at it and its so fiddly I thought I may as well save myself a job in the future.

[comfybadger]

Just ordered up a new clutch master cylinder, the old one worked but looks original and while I am at it and its so fiddly I thought I may as well save myself a job in the future.

Can I ask you where you are getting your new master cylinder from and how much it is costing you?
I have had nothing but trouble with the replacements I have been able to source and am currently in need of my third replacement in as many years. Whatever you do, do not discard your old one!

[paul66beetle]

I usually get OEM quality replacement parts. Never had any problems before. I either use GSF or EuroCarParts as get discount from both.

I have kept the original one.

I am surprised you went through so many. Was the clutch clevis pin adjusted properly? It wasn't going too far was it and damaging it?

[paul66beetle]

Old ones are being sold on Ebay!!(not mine I hasten to add)
http://www.ebay.co.uk/itm/VW-T25-parts- ... 1205766777" onclick="window.open(this.href);return false;

[comfybadger]

Old ones are being sold on Ebay!!(not mine I hasten to add)
http://www.ebay.co.uk/itm/VW-T25-parts- ... 1205766777" onclick="window.open(this.href);return false;

The master cylinders I had trouble with leaked at the inlet seal where fluid tops up from the reservoir. I gave up sending them back and replaced the seal with the one from my original cylinder; I think they were just too small for the job. My current problem it turns out was due to the bracket holding the slave coming loose; it felt like the master had gone and I jumped to that conclusion because of my previous experience. I cursed very loudly!