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Pelican Technical Article:

Brake Booster Replacement

Steve Vernon

Time:

8 hours8 hrs

Tab:

$250 to $350

Talent:

**

Tools:

13mm deep socket, 11mm flare nut wrenches, power bleeder

Applicable Models:

VW Golf GTI (1999-00)
VW Golf GTI 1.8T (2002-05)
VW Golf GTI 20th Anniversary (2003)
VW Golf GTI 337 (2002)
VW Golf GTI GLS (2001)
VW Golf GTI GLX (2000-01)
VW Golf GTI VR6 (2002-05)

Parts Required:

Brake Booster

Hot Tip:

Use paper towels and plastic bags to contain any fluid leaks

Performance Gain:

Better braking

Complementary Modification:

Replace master cylinder

Without a doubt, your brakes are the most important systems on the car.

Replacing the brake booster on the GTI MkIV is not difficult, it is just a tight fit, but it should take no more than eight hours including bleeding the brakes. The first step is to disconnect the battery and remove the airbox and MAF sensor. You will also need to remove the brake pedal switch, master cylinder and ABS control module. It is possible to remove the brake booster with the master cylinder attached but you will need to separate them to replace the booster so you might as well separate them in the car and give yourself more room to work. Please see our articles on how to perform these tasks.

When you are finished you will need to completely bleed the brakes. DO NOT drive the car without completely bleeding the brakes

With all of the previous steps complete you will be left with the brake booster (red arrow) attached to the firewall.
Figure 1

With all of the previous steps complete you will be left with the brake booster (red arrow) attached to the firewall.

Move to the interior and remove the cover panel behind the pedals.
Figure 2

Move to the interior and remove the cover panel behind the pedals. This panel protects the steering shaft and can be removed by unscrewing the two plastic screws (red arrows) and removing the panel.

There is a bracket between the brake and clutch pedal.
Figure 3

There is a bracket between the brake and clutch pedal. Use a 13mm socket and remove the two nuts (red arrows).

Remove the bracket (red arrow).
Figure 4

Remove the bracket (red arrow).

The booster shaft is connected to the back of the brake pedal by several different means.
Figure 5

The booster shaft is connected to the back of the brake pedal by several different means. On our project car the shaft was held in place by two plastic clips (red arrows). Pushing the clips back allowed us to remove the shaft from the brake pedal. Note; it is a really tight environment to work in and you will need patience to remove it without damaging it. It is a good idea to order this part before you start the job in case you damage it in removal.

There are four 13mm nuts holding the brake booster to the firewall and pedal box.
Figure 6

There are four 13mm nuts holding the brake booster to the firewall and pedal box. You will need a 13mm deep socket to remove the four nuts (red arrows, three shown).

With the four nuts removed you can wiggle and pull the brake booster out from the front (red arrow).
Figure 7

With the four nuts removed you can wiggle and pull the brake booster out from the front (red arrow). Installation is the reverse of removal. When you are finished you will need to completely bleed the brakes. DO NOT drive the car without completely bleeding the brakes

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Page last updated: Sat 12/3/2016 02:36:32 AM