So i have just swapped over the servo on my 91 GT, the servo was being dodgy and removing the old one revealed some major rust had taken hold on it.

 

Anyway i've fitted a replacement servo, taken off a 2f, i haven't adjusted anything on this new servo. My car is running a rear disc setup, with VW2 fronts and a 22mm master cylinder, this has all been fitted for a couple of years and been working perfectly.

 

With the new servo fitted, the brake pedal sits lower than the clutch pedal (they used to sit level), and the point at which the pedal goes solid is also lower. These i can live with, but the pedals new position is too low to switch off the brake lights, so they stay permanently on.

I have taken apart the old servo, and the only adjustment i can see is on the master cylinder side, which would change the bite point, but not where the pedal sits at rest. Being honest i'm stumped, its like its not seated correctly on the bulkhead, but the three mounting bolts are tight, look even and none of it looks crooked. I have released the master from the servo to check its not that, and the pedal indeed is still incorrect with no master.

I can only think i'll have to strip it off again and compare with the old servo/check its seating. But before i do, anyone have any bright ideas?

 

Thanks guys

I have no idea if the 2f servo is compatible with that of a GT, so hopefully, someone else will pick that up.

What I would say though, is be very careful about attempting to close the distance between the master cylinder and the servo push rod. You MUST have clearance here, otherwise there is a risk that the master cylinder piston will be pushed forwards when the brakes are OFF, this may not be sufficient to apply the brakes, but if the recuperation port in the M/C is covered by the piston, then fluid can't return to the reservoir and as the fluid warms up in use, THEN the brakes could start to apply.

 

Regards

PS

If you do remove the servo again, I would suggest that you take some measurements and compare them with those on the old unit.

Edited 14 June, 20188 yr by caretakerplus
PS

Seems a strange one, because all 2f servos are the same, including GT and g40 as far as I'm aware. 

All the servos are the same in the 2f Polos regardless of spec or engine.

I know the 22mm master cylinder does give you a longer pedal travel.

I would do as suggested above, remove the new unit and compare new to old.