Anyone install a German MC to replace what the VS comes with, Chinese copy and find the new boot will not fully slide over the existing pushrod. Apparently, in the existing brake pushrod, the first diameter entering the boot is smaller than the second half- closer to the pedal connection. the boot will not slide completely on causing it to fold back on itself. Any suggestions without having to disconnect the brake lines and unbolt the MC? Looking at the situation my first thought was to loosen up on the MC mounting bolts and unscrew the pushrod from pedal to remove it. Once pushrod is out of the boot heat up a screw driver shaft of slightly larger diameter to the pushrod's larger size and pass it thought the rubber boot- am I thinking incorrectly?
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I don't think the boot needs to be modded. The "fold back on itself" isn't really a problem—it's the way you find them in nature (or, at least in old Beetles). I think just install it like it is and be happy.
Edsnova, you are right. After heating a larger diameter to open the boot hole, it was fully extended and butts up against the pushrod adjustment nut. So, now when compressing the brake, it does fold back, not as dramatically as before. I have now two option, be happy with what I have or tear the boot off and done with it. If the boot is removed and the MC every breaks its seal, it will run into the fire wall and not on the interior carpet. Its madness I say
I think that is all by design to keep fluid from leaking onto your floor. It is supposed to be tight.
Bill, thought the same. But, not to crazy if the MC fails the fluid is trapped in the boot and compressing it would squeeze brake fluid onto my carpeting. The old Chinese MC I had before had no boot and when it leaked the fluid ran between the firewalls.