General Brake Servo Upgrade

[Sprox]

Ok!
i've looked at what's involved!

The good news is:

1. It looks like you can use the existing brake pipes - the existing ones run past where the new serov and mastercylinder is going to be fitted!

That's it for the good news!

2. The bad news

A list of things we know you need:

a. Servo and master cylinder (does the old panda cylinder fit the servo?)
b. Mounting bracket for servo
c. Brake pedal gear - from Servo to Pedal
d. Inlet manifold from Uno 999 Fire non-injection, or form Panda 4x4 - it has a vacuum pipe to which you attach, via a rubber tube, your servo

THe brake pedal gear is the trickiest - I am as yet unsure wether you need the ENTIRE Pedal mounting plate (in which case you need to disconnect steering, clutch, throttle etc.
or wether you can just add to the existing Pedal mounting plate, the specific parts that you need.
THe clutch pedal runs off the same spindle as the brake pedal . . . .
I've got some pics:

 

[petel]

You will need the whole kit from a 4X4 or one of the later 4X2's. The front two brake pipes are different, though the same at the wheel ends. The master cylinders for servo and non-servo have different part numbers and may not be interchangeable. Wiring for the brake fluid low level warning switch will have to be extended or re-routed. The mounting for the clutch cable at the pedal box end may be a problem.
Rgds.

 

[Sprox]

Ok! Thanks Pete!
I've got the master cylinder with the servo!
Brake pipes - are they different guages?
Will check the clutch mounting when I get the mounting plate . . .

 

[petel]

Brake pipes are the same guage. If you need to adapt the clutch cable to the pedal box will depend on which pedal box assy you aquire for the job.
Rgds.

 

[Sprox]

I'm considering moving the Battery and Mounting tray to the other side of the Engine bay ( Red will carry an emergency inflator kit like my old Copen did - He doesn't carry a spare Cinq alloy).

This will dispense - hopefully - with the need to change all the pedal assembly.
I just have to check that the master cylinder does not reach the rocker cover!!!!! DId I have a ruler when I wanted to measure this? I did not! looking at it, I should have 2 - 4 cm room to spare - possibly more. Do you think this gap is large enought to cope with any rocking engine vibration?

It looks like the Servo mounting plate will fit straight onto the existing bolts that hold the master cylinder to the bulkhead - and the spacing of the pedal/servo connection also looks the same . . . . .

Selecta Discs and pads and calipers are going on the front anyway....:yum:

 

[petel]

Hello Graham.
I had not considered this approach before so, will be interested to see how you get on.
Rgds.

 

[Sprox]

ok! We have to remember that Pandas were designed LHD! sticking everything on the Right Hand side ..... they just shifted everything directly to the right!!! Is the Master cylinder on the left hand side on non servo LHD models? I assume it is...

 

[Alan.D]

The LHD servo is on the same side as the UK cars

 

[Sprox]

Ok, definitely not enough room to locate the Servo on the Right hand side
BAck on with replacing the pedal assembly......

 

[panda-sport]

Sprox, have you looked at the possibility of using remote servos, you have the room to mount them on the left hand ledge as you run without a spare.

cheers Damon

 

[Sprox]

Sprox, have you looked at the possibility of using remote servos, you have the room to mount them on the left hand ledge as you run without a spare.

cheers Damon

No Damon! I don't know what one of those is?
But at least we know that the pedal assembly WILL work