#1: Servo Problem (2002) Author: mikemcg93, Posted: Fri Aug 12, 2016 11:10 pm ---- There is a loud hissing coming from the passenger footwell which I believe to be the servo. I had pushed it into place earlier today and it went off and was quiet but after accelerating it has started to hiss again an stops when braking and sometimes when accelerating. Is this repairable,how much will it cost, if I can do it myself is there a guide anywhere. Thanks in advance
#2: Re: Servo Problem (2002) Author: Seanie280672, Posted: Sun Aug 14, 2016 6:45 am ---- very easy to change, just make sure you get the same part or very similar, or even brand new (which isnt cheap), ive got a 2003 GTI and used one off a 2001 GTI, its working fine now, got mine from a guy breaking a 2001 GTI.
There is 4 bolts to remove under the glove box which hold the servo in, you can just about get to it if you get on your hands and knee's, 13mm long socket with a long extension, also there is a pin there to remove which connects the rear servo prongs to the brake pedal arm, a bit tricky to remove, but get down there with a torch and you'll see how it comes off.
I had to remove the battery and battery box to get to mine under the bonnet, but without pictures I wouldnt know the layout of your engine, 8mm bolt for the negative terminal on the battery, 3 x 10mm bolts to remove the battery box itself.
remove the 2 13mm bolts which hold the master to the servo, I also had to remove the clutch pipe from the master (hydraulic clutch), it just pulls out, stick a large screw in the end of the flexi pipe to stop brake fluid dripping everywhere, pull the master out from the servo and move to one side, the pipes are pretty flexible, this saves having to bleed the brakes later.
remove the vacuum pipe from the servo, again this just pulls out, now you can pull out the servo.
Things to watch out for when refitting, make sure the centre pin in the servo engages with the centre hole of the master, if it doesn't you'll have no brakes. I also put a bit little bit of grease on the end of this pin before fitting the master to the servo, just to help with movement, its quite a big pin and actually difficult to get wrong.
also make sure when you push the new servo into place that the brake pedal bar sits within the 2 prongs on the back of the servo, (under the glove box) then line the holes up and push the securing pin back in. it took me about an hour to do the complete job.
this is my old thread here, watch out for that little bugger of a rubber O ring on the back of the master too, mine dropped off without even realizing and had to take half of it apart again just to refit this: www.206info.co.uk/Foru...64987.html
Will see if I can post some pictures later.
#3: Re: Servo Problem (2002) Author: iainlovatt, Posted: Mon Aug 15, 2016 7:06 am ---- If you dont feel competent with replacing it then i would suggest taking the glove box out completely and take it down to the local garage. That what i did many years ago.
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