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Brake Booster Problem 700 1991

The brake booster recently failed on my '91 740 with ABS. I purchased a rebuilt unit and turned in the core. Now it appears that the rebuilt unit doesn't work. (Not the same problem as before) In looking at the unit, it appears that the plunger is not long enough to reach the piston in the master cylinder. I lengthened the plunger as far as it would go, but I still seem short. The autoparts store says that my problem is that I haven't bled the brake system properly, but I didn't even disconnect the brake lines. The unit has the 8" diaphrams, which my dealer confirmed is the right unit (vs. the 10").

Any suggestions would be appreciated.






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