Bigger brake booster, improved brakes.

[ALIKA T3]

Got it, my bad, I thought it was the piston size but that's right, this one has 2 pistons the name doesn't apply to the piston size.
_________________
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

[Jake de Villiers]

I finally made the swap to the BMW booster I picked up years ago.

A series of delays (a move to Tsawwassen after 26 years in our house in Crescent Beach, a heart attack and bypass surgery followed by remedial surgery to close the hole they left in my chest...) meant I have had the parts kicking around for ages.

So, steering wheel out, dash out, master out, pedals out (!!!) New clutch and brake masters in on top of the 10" ATE booster and much, much bleeding.

And now? The pedal is atrocious, the diametric opposite of "confidence inspiring". Alika's description of stepping in a pile of dog poo is right on. Its mushy as hell and the travel is really excessive - like getting too close to the floor excessive. The booster is much more vocal than the original.

I adjusted the pin very carefully and we have bled the brakes to the bone. When you bleed off the vacuum, the pedal is quite firm with only about an inch of travel.

Did I miss a step? Is there a gasket I should have replaced? Is there an adjustment I can make or do I just take the dash apart again to re-install the OEM booster?

Thanks for any advice, Jake
_________________
'84 Vanagon GL 1.9 WBX
'86 Westy Weekender Poptop/2.5 Subaru/5 Speed Posi/Audi Front Brakes/16 x 7.5 Mercedes Wheels - answers to 'Dixie'
@jakedevilliersmusic1
http://sites.google.com/site/subyjake/mydixiedarlin%27
www.crescentbeachguitar.com
www.thebassspa.com

[wesitarz]

I had the same with my G-57 Van Cafe big brake. Maybe it's the different booster that accentuates the caliper flex inherent in the G-57. When you press the brake pedal can you see the caliper flex kinda like a wrist flex? Fixed mine with a caliper stiffening kit.
For some reason I had to grind off a bit of metal to get the clips to fit on but doable with a 4 inch gringer with calipers still attached to brake line.
From Tyrollsports and maybe others:
https://www.tyrolsport.com/braking/tyrolsport-brake-caliper-stiffening-kit-for-vw/audi/

Edit: https://www.facebook.com/watch/?v=200468467513057

[ALIKA T3]

It's not really the flex, it has to do with piston area vs master size.
I had the same happening on stock floating calipers and fixed 4 piston calipers.

Jake, we're happy you're still around tinkering on your van!

Take care!
_________________
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

[crazyvwvanman]

The 60 on the caliper with 2 side by side pistons actually does refer to the piston size, indirectly.
That caliper has a total piston area equivalent to a single 60mm piston.
So it uses the same master cyl fluid volume/pressure as a 60 so they mark it 60.

Mark

[MarkWard]

The bigger booster should lessen effort. I’d suggest driving it a bit. You may find the actual braking is fine. The dog poo feeling is likely from the additional assist.

[Jake de Villiers]

Thanks for the feedback you guys.

I don't have the front wheels off to see the flex but that's an interesting observation.

I drove it again yesterday and it does stop okay but I still hate the mushy pedal feel. I should bleed it again before I yank the dashboard apart.

Thanks, Alika, its good to see you're still engaged with the Vanagon community.
_________________
'84 Vanagon GL 1.9 WBX
'86 Westy Weekender Poptop/2.5 Subaru/5 Speed Posi/Audi Front Brakes/16 x 7.5 Mercedes Wheels - answers to 'Dixie'
@jakedevilliersmusic1
http://sites.google.com/site/subyjake/mydixiedarlin%27
www.crescentbeachguitar.com
www.thebassspa.com

[syncrodoka]

Did you manually adjust the rear brake shoes? That makes a surprising difference in pedal height and feel.

[Jake de Villiers]

[ALIKA T3]

[wesitarz]

Caliper stiffeners, larger 25mm MC (for a BMW 740i), SS flex hoses and brace for the MC flex was my solution for an acceptable pedal feel.

[MarkWard]

Going to a larger diameter master cylinder will increase pedal effort. It’s possible to use a 25mm BMW master, but it takes some fitting. It’s documented in another thread.

[ALIKA T3]

Some people mount a 1" Transporter T4 master and booster but that's a heavy mod for the cluster and all.
_________________
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

[Jake de Villiers]

Thanks everybody for sharing your experiences with the E30 booster.

Last weekend I went back in and replaced the bigger booster with the OEM part. The pedal feel is very good now, high and firm, though stopping power is still less than breathtaking.
I'm not sold on the Akebono pads and Van Cafe shoes on the van currently. It stopped a lot better with the Porterfield shoes and EBC YellowStuff pads.

I only had a few thousand miles on the EBC pads when I was persuaded to try the Akebonos and I'm sure I put them in a box when we moved, but I can't find them...
_________________
'84 Vanagon GL 1.9 WBX
'86 Westy Weekender Poptop/2.5 Subaru/5 Speed Posi/Audi Front Brakes/16 x 7.5 Mercedes Wheels - answers to 'Dixie'
@jakedevilliersmusic1
http://sites.google.com/site/subyjake/mydixiedarlin%27
www.crescentbeachguitar.com
www.thebassspa.com

[MarkWard]

When switching compounds you need to bed them in. This process transfers pad material to the rotor giving you the grip you are looking for. Follow the manufacturer’s procedure. If not, look at hawk brake for their bed in directions.

Also, performance compounds have a best temp working range. Most driving Vanagon brakes aren’t that hot, so a compound for lower temps is better. You need to know your operating temp when choosing compounds. Higher is not always better.

I’ve got performance friction on the front, but their street compound. Brakes have always seemed better with some temp in them. Problem is in a panic stop, generating temp is an option. Not saying this is your problem.

[Jake de Villiers]

[do.dah]

Why not porterfield on the front?

[Jake de Villiers]

[Christopher Schimke]

[do.dah]

Was just curious why you had porterfield on the rear and not on the front.
Christopher's answer is the same as I'd say.
I have dark/black wheels, so the dust doesn't bother me as much as someone with light colored wheels,, nontheless, I see it and hafta clean them due to ocd...