I rebuilt an original girling brake booster using one of those rebuild kits. I have heard mixed reviews on how effective these units are after a rebuild (even when they are new!) - so I did this complex project (for me anyways) with some trepidation.

Well, I installed the rebuilt unit. To my amazement, it works and it makes a significant improvement in the brake effort. Not like my "modern" 245, but the braking effort is noticably easier.

Now that it is working, I have some questions:

The pedal is a bit mushy (it wasn't before installing the booster). It's not bad, but not immediately firm. I have bled, re-bled, the system, with no improvement (sigh). Is this normal with the booster? Is there air in the booster that is trapped? If so, how do I get it out?

There is a point where the booster seems to "kick in". Not suddenly but at a certain pedal push point, then braking markedly increases. Is this normal or is there a sticky valve or something in the booster? If the latter, will it go away with more use?

I have a dual master cylinder, and right now the boost is only to the front brakes. I'll get a splitter so the boost and be applied to both front and back. Given the current set up, could this cause any problems? Could this be the cause for any of the above mentioned symtoms?

With the vaccuum line to the booster, will I have to re-adjust the carb mixture settings?

As always, working on a 122 makes life interesting.

Thanks all and happy Easter.

waggin

220 1965 wagon
245 1985 turbo wagon