Vanagon Electric Brake Booster Install

[BernieTime]

Installed an electric brake booster--called a Bosch ibooster--last night on my Doka.

Has anyone else done this?

I don't have any pics at the moment... I will update this thread next week when I am back with my Doka.

It was fairly straight forward. I retained the stock brake pedal. I had to completely remove the dash and steering column. I used an ibooster from a model 3 tesla and changed the brake fluid reservoir to fit under the dash. There are a couple of other cars out there that use the ibooster too so you can avoid the price mark-up that comes with the "Tesla" name.

Why? 12v electric brake booster gives better performance compared to 40 year old vaccum assist (skeptical? Google it...). You also get to used your brakes more than once if your engine dies....
Finally, its really easy to wire if you already are running an electric power steering kit (like I am).

Again, I'll update this with some pics and a quick how-to guide next week.

[shagginwagon83]

This sounds rad, and a beautiful solution for the various flavors of big brake kits out there.

[ALIKA T3]

That's super interesting, I'd love to see the pictures!

Not that I will ever do it (the less electric stuff the happier I am) but I appreciate creativity applied to our beloved Vanagons!
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Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget

[Jake59]

Yes, More information please. like what # item number and lots of photos if any mods to the item or van were necessary.

A Google search for "Bosch ibooster" only sent me to a bunch of Tesla links.

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Curent ride: 87 2WD Westy, 2012 Jetta Sportwagon 2.5S

Past Rides: 62 (23 window) Bus, 64 Ghai convertable, 68 single cab, 72 Super Bettle, 78 Bay window Bus, 84 GTI.

[dublife13]

I am very interested in this conversion both for the performance and the space in the dash, excited to see some pictures.

[RoryGirl]

Give SuperfastMatt a sub...


Link

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1991 Twin Slider VR6
1985 Audi 4k

[11BC2]

[JohnL99]

This is cool. With all the trouble finding replacement boosters this might be well timed. I have Toyota Yaris electric power steering on mine so you know I am interested.

[AndyBees]

Subscribed for updates and pics.
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'84 Vanagon Tin-top, ALH TDI, two trips to Alaska, 2014 & 16. 1989 Tin-top unmolested.
1983 Air-cool, 225k miles, 180k miles mine, seven trips to Alaska from 1986 thru 2003. 1975 Bay hopeful.

[SnowDaySyncro]

I've been eyeing this as well, as part of my dream of eventually converting my TDI Syncro to 4xE.

Running in FWD EV mode will require the brake booster and power steering to be electric. In the meantime, it should theoretically decrease engine load and increase efficiency if I eliminate the need for a vacuum pump.

[dieseltdi]

Was wondering what master cylinder you used? The one that is mounted on the power unit? I am about to have to completely disassemble my dash to install my Behr ac unit so……
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When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[dieseltdi]

Hey OP! Are you going to give us a follow up with pics?
_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[midwestOutreach]

Yes, please more details!
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In the garage:

• 90 Vanagon Carat
  
• 80 Vanagon Westy
  
• 03 Discovery
  

[BernieTime]

Yes! My Doka has been in storage and I've only been able to access it once a week. I am towing it down to my shop this weekend and I'll take some better pics. I have a full step by step write up in the works so this thread can be used as a reference in the future! Sorry for the wait.

[dieseltdi]

Great!
_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[BernieTime]

Here's a sneak peak! I am putting all my pics and advice into a comprehensive how-to.
Biggest take away: Most of the stock brake fluid reservoirs that come with any version of the iBooster won't fit our vans.
HOWEVER, there is a master cylinder from a different car that is a direct bolt-on to the iBooster which fits perfectly in the Vanagon and works with the stock brake lines.
More on that later after I 100% confirm the compatibility.

[dieseltdi]

Waiting with keen anticipation. I am about to have to remove my dash for AC work so this may be the time and place for a change to a more modern system.
_________________
When a clown moves into a palace he doesn’t become a king, the palace instead becomes a circus. — Turkish proverb

Those who will willingly sacrifice freedom for security, deserve neither.

Currently:
1982 Vanagon Westy TDI conversion with Coast Mt. Hightop - SKYE
2025 Hyundai Ioniq 6 EV
2015 Golf Sportwagen S TDI
Way too many previously owned to list!

[shagginwagon83]

As someone with electric power steering, I am very interested also. That unit has worked perfectly since it was installed.

It is beautiful to see wrecked electric cars bringing vintage cars back to life.

I too am overdue for a dash-out servicing. I have a BMW reman booster on the shelf - which now I am likely to sell given this project. Love the ability to adjust with this unit!
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"Jo Ann" - '83.5 Westfalia EJ22e w/Peloquin

[Run8Stud]

Would this type of conversion work for stick-shift vans? Or would another reservoir be needed for the clutch? I ask out of ignorance as I haven't dug into the brake-booster or clutch yet, but I think they share the one reservoir.
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John G. - 1987 Westy GW 2.2 5-Speed

[panzer]