Removing brake booster - '81 FI

[Kevin1]

Who has replaced the brake booster in a FI car? I seem to have run into a mechanical catch-22! The brake booster can't come out past the intake manifold, and the manifold won't come out past the brake booster and the crankcase breather. The only way I see to gain clearance for both is to pull the cylinder head, which isn't that big of a deal, but before I do I'm asking:

Anyone know of a trick to get the booster out and a new one in without removing the head?

[ClarkTheShark]

You should be able to get the intake manifold out without it hitting the booster. try again.

[ClarkTheShark]

You should be able to get the intake manifold out without it hitting the booster. try again.

[narfire]

It does come out, but I had to loosen the alternator and push it out of the way. Also I undid the fuel rail at the pres.reg and again pushed it out of the way. Slid the booster out the front more than up.

[4uall]

This might help

http://www.fiatspider.com/f08/viewtopic.php?f=9&t=7125

[Kevin1]

After a little time to let the frustration pass, plus the help of a set of younger, stronger hands - and the intake manifold did come out, making room to remove the booster. Getting the fuel rail out of the way was the key to the puzzle. The new (old) booster tests good with a vacuum pump, so I think with a little forearm origami applied to the bolts up under the dash we'll be on the road again. The upper left bolt with the spring bracket attached is proving to be more fun to put back than it was to remove.

Thanks for saving me from myself - I was THIS CLOSE to pulling the head off to make room.

[spider2081]

Hope its together soon. Looking forward to the Maine weekend.

[Kevin1]

It took a weekend of learning new ways to fold myself into the space under the dashboard to get the booster bolted in, but it is finished. A couple of rounds adjusting the acorn nut were required before having it all working correctly. To be honest this was one of the more difficult repairs, mostly because access is awkward at best.
It will take me a day or so to straighten myself out again.

[joelittel]

How did you adjust your acorn nut? Mine simply rotates the entire shaft when I try to adjust the nut, and I can't figure out a way to hold the shaft while adjusting the nut.

[azruss]

I held the shaft with vice grips. be careful not to clamp on a section where the seal is.

[Kevin1]

How did you adjust your acorn nut? Mine simply rotates the entire shaft when I try to adjust the nut, and I can't figure out a way to hold the shaft while adjusting the nut.

With the master cylinder removed, the rod with the acorn nut pulls straight out of the booster. It is easy to adjust once it is out. For what it is worth, mine turned out to have too little adjustment with the locking nut in place, so I removed the locking nut, ran the acorn nut all the way down, and presto! The pedal is slightly lower than before so I will now shim it to get it just right.

[joelittel]

Thanks guys. I'll see if i can pull my rod out and make the adjustment.