jwalker1970

2003 Beetle 2.0L Turbo gas 6 speed manual

I noticed a loud hiss under the dash. Under further examination, the vacuum leak was coming from the rod that pushes through the firewall to the brake booster (brake booster was bad).

I verified the hiss stopped when unhooking and plugging the vacuum line to the booster pod.

I easily removed air cleaner box, battery and master cylinder to clear enough room to pull the brake vacuum booster. The 4 bolts under the dash connecting the booster to the firewall are no problem either.

Question: How does the rod remove from the brake "U" shaped brake pedal itself? There is some sort of plastic retainer inside the track of the brake pedal that holds the rod in.

I found a used vacuum booster at a local salvage yard for only $40. I don't want to break any part that's VW dealer exclusive.

Thanks in advance.

jwalker1970

I used a die grinder to cut the brake booster rod in 2. then I unbolted brake pivot bolt & removed pedal. Then I gently heated plastic retainer and pryed it from brake pedal. Then rod will pry out. I was able to re-use the green plastic retainer because I removed it very carefully.