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" ". REPLACEMENT SERVO

Fitting instructions for
REMOTE VACUUM
SERVQ UNIT BOOST RATIO 1.90:1

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(For single
, line braking systems)
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General fitting instructions

To ensure correct installation of the remote vacuum servo unit, thoroughly

read and adhere to the fitting instructions prior to carrying out any work
on the vehicle.

Introduction
The vacuum servo unit is incorporated into the hydraulic braking system,
remote from the master cylinder, as an intermediate stage operating
between the master cylinder and the brake assemblies. The two main
parts of the servo unit consist of the vacuum servo mechanism and the
hydraulic slave cylinder assembly. These component parts are bolted
together so that the slave cylinder piston is in line with, and is operated
directly by, the servo push rod ..

A plastic ncm-return valve is fitted into the vacuum shell and an integral
air cleaner is incorporated to prevent foreign., matter entering the air
control valve chamber.

The servo unit is designed to give no assistance with very light brake
application. In the absence of servo assistance due to loss of vacuum, an
unrestricted passage for the fluid will exist. The brakes can still be
applied, therefore, by the normal action of the pedal on the brake master
cylinder, but this would demand heavier foot pressure to achieve the
same degree of braking as with servo assistance.' When this servo unit is
used to replace a non-Lockhead servo or is installed on a vehicle
previously without a servo, the following installation. recommendations
must be observed.

Note:
Not for use on vehicles with tandem or dual line braking systems
except for specific applications where twin servo units are fitted.
In this instance, units must be replaced in pairs to maintain the
correct brake balance.

I~portant:
Fitting a brake servo unit will not make faulty brakes reliable. Any fault in
the vehicle braking system must be rectified. Therefore before fitting
the new servo unit, ensure that the braking system is in good
working order.
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 Note:
A. When 'changing brake parts the need for absolute cleanliness
is essential. Therefore ensure that hands are free of grease and
dirt. Always use fluff-free cloth or paper towelling for cleaning
purposes.
B. Ensure a sufficient quantity of Dot 4 brake & clutch fluid is
available for bleeding the braking system and topping up the
reservoir. Where possible brake fluid should always be stored and
dispensed from the original tin or bottle. Care must be taken to
prevent both dirt entry and contamination especially in the mouth
area of the master cylinder reservoir during the operatio,l.

Prior to fitment of the brake servo unit or removal of an existi:-Ig servo

installation, thoroughly clean the outer surfaces of the unit (\N~ere
applicable) and around all relevan~ hydraulic pipe connections using
methylated spirit as a solvent. Do not use petroleum-based products
for cleaning braking system components, i.e. petrol or paraffin.

On the majority of vehicles a 3-way adaptor is used into which are

coupled the supply pipe from the master cylinder outlet port c:ld the pipes
feeding both front and rear brake assemblies.

Removing existing installation

1. Disconnect the battery.

2. Disconnect and remove the vacuum hosepipe that conlects the
servo unit to the vacuum pump/manifold.
3. Disconnect, remove and discard the hydraulic fee.d pipe from the
master cylinder outlet port to the 3-\'1ay adaptor. Sea' off the
hydraulic connection points to prevent loss of brake fit..:id and
ingress of foreign matter.
4. Unbolt the existing servo unit together with any moun:ing
brackets, where applicable, and remove from the vehi:le.

Note:
Brake fluid is injurious to paintwork, therefore when removing the servo
unit from the vehicle care should be taken to ensure that no fi'Jid is spilt
onto the painted surface of the bodywork. Should fluid spi!lage occur,
wash off immediately with copious amounts of cold water.

The following general instructions apply to remote servo instc: ation kits.
Obviously all vehicle types cannot be quoted, but by observing these
instructions the installation kit can be used for the majority of '.'ehicles
with single line braking systems.
vI/here the hydraulic piping, supplied in the fitting kit, needs tv be
shortened it will be necessary to use a Bundy flaring too to re:orm the
pipe end.
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Location of new servo unit and brackets

1. It is essential that the servo unit is fitted to the integral body or

'chassis (i.e. Not to the engine) thus preventing the brake
pipes being subjected to vibration or flexing.
2a. It is an advantage to locate the servo within the engine
compartment whenever possible to safeguard the unit and to
keep the hydraulic pipe runs to ;;J minimum length.
2b. Should it become necessary to fit the servo unit in an area on
the vehicle prone to dirt, grit or water ingress e.g. under body
wings, it is recommended that an extension hose be fitted to the
air control valve inlet by carrying out the following modification,
prior to installation.

Method:

Carefully prise off the plastic air filter cap. Note components retained
By the cap, which is a snap fit, may become dislodged during removal.
Therefore care must be taken to prevent parts becoming lost or
damaged. Extract the form washer from within the existing air filter cap
and replace. Fit the air filter cap to the air control valve ensuring that
the rubber seal, seal retaining cap, compression spring and filter
element are all correctly located. (See Fig.! for details). Connect one
of the vacuum hoses from the kit to the inlet pipe on the filter cap,
secure with clip provided. On installation, locate the other end of the
vacuum hose in a suitable position away from dirt or grit.

3. Ensure the hydraulic slave cylinder is at least ,six inches away

from any part of the vehicle exhaust system, otherwise fluid
vaporisation from local heat could occur.
4. The servo unit need not be mounted below the level of the brake
fluid reservoir, but keep the difference in height to a minimum.

5. With the aid of the mounting brackets and fixings provided in

the kit install the servo unit with the hydraulic slave cylinder
outlet port inclined upwards between 25° and 45° from the
horizontal plane. (See Fig.2). The air control valve should be
situated at least 30" below the centre line to assist when
bleeding the hydraulic system. (See Fig.3).

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Fitting hydraulic piping

With all relevant connection points clean and free from ingress of foreign
matter, using the new Bundy piping supplied in the kit:

a. Connect up the feed pipe from the brake master cylinder to the servo
slave cylinder inlet port. '
b.. Connect up the supply pipe from the servo slave cylinder outlet port
to the 3-way adaptor.

When bending brake pipes to shape, great care must be taken to

avoid kinking. The best way to obtain a good curve is to bend the pipes
smoothly round a mandrel of suitat?le diameter. Using existing clips on .
the vehicle, ensure pipes are properly secured and cannot chafe or foul
other components. Where a long length of piping is fitted e.g. from one
side of the vehicle to the other via the bulkhead, secure the pipe to the
bulkhead to avoid vibration. Additional pipe clips are available for use
where necessary. On some vehicles where space is limited, it will be
helpful to use banjo and bolt fittings in the tappings of the servo slave
cylinder to avoid a severe bend in the brake pipe. (See Fig.4).

Note:

No attempt should be made to cut and reflare existing brake pipes

in situ, as problems could arise with contamination through
ingress of foreign mater, i.e. swarf ..

Vacuum hose, In line non-return valve (where fitted), and fittings

The servo unit must be connected via a vacuum hose, running from the
plastic non-return valve located in the servo shell to a suitable vacuum
source e.g. the engine induction manifold or vacuum pump. On some
vehicles the manifold is already tapped and fitted with a removable plug,
otherwise it will be necessary to drill and tap the manifold.

Three manifold adaptors are available, each with a different thread size to
suit various applications.

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These thread sizes are:-

1. 1/8" x B.S.P. taper. This is self-sealing and should be used when
the manifold is not already tapped. Drill the top wall of the
manifold 5/16" and tap with a l/S" B.S.P. taper tap. The manifold
should be removed from the engine for this operation.
2. 5/8" x 16Whitworth thread. (Use with a copper gasket).
3. 5/8"x 18 U.N.F. thread (Use with a;copper gasket).

Fit the relevant adaptor(and the copper gasket, if a 5/8" diameter

adaptor is used), and attach the vacuum hose from the kit, securing with
one of the hose clips provided.

In a convenient position, preferably at the highest point in the

vacuum hose run, an in line nOfl-return valve is advisable on high
performance vehicles. Cut the nose and connect up the two sections to
the valve unit, secure with hose clips supplied. Ensure that when fitted.
the arrow on the non-return valve is pointing towards the servo.
(See Fig.4). :

Important:
To protect the servo unit and non-return valve from fuel
contamination, especially on a petrol engined vehicle, a 'U' trap
must be formed in the vacuum hose route.

It is essential the vacuum hose inclines downwards from the servo

and that the' U' trap is formed below the level of the servo and
the in line non~return valve (where fitted), i.e. by looping it between
the inlet manifold and non'-return valve so that point' x' is lower than
points' V' and' Z' as shown (See Fig 4). Where the vacuum hose
traverses the engine secure in position with plastic ties. Secure hose
connection at the servo with the remaining hose clip.

Bleeding and testing system

1. Reconnect the battery.
2. Using new DOT 4 brake & clutch fluid or fluid as recommended
by the vehicle manufacturer (conforming to SAE J1703
specification) bleed the braking system in accordance with the
appropriate vehicle manual. With the system properly bled, firm
resistance should be felt at the brake pedal, if difficulty is
experienced in achieving a "good bleed", then the bleeding
process will be assisted by "cracking open" the brake pipe tube
nut at the servo outlet connection whilst depressing the brake
pedal. Surround this connection with clean "fluff free" cloth to
capture escaping brake fluid. When the pedal is fully depressed
retighten tube nut, repeat this process several times if necessary.
When completed, "top up" the fluid reservoir to the correct level.
3. Start the engine and apply the brakes several times. Whilst an
assistant depresses the brake pedal, re-check for fluid leaks
4. particularly where new connections have been made. Road test
the vehicle, and finally check for fluid leaks.
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Servo Kit
(LE72696)
General Vehicle
Singer
Replacement
- .'
64049178
64949023
64049354
(LE2696)
Installation
64049330
application
Chamois
(LE72696)
Girling
application
Girling Power
(LE72696) ,
MKs.
Stop TRIUMPH
III
MG
guide
GIRLING
Kit/servo 1100
11,
MGA Californian
(Triumph
MOdels)
Minx
KitsI . TALBOT
Singer)
Hillman
11, Herald
1300
Imp
Interchangeability)
Land
&
for
Sports
Lotus
r-10rganApplication
Coupe
(All
Rover models)
remote
2-str.
Elan
Plus
Hillman
Saloon
r-10dels)
(Hillman,
fv1.G.fvlidget MKs.
+S.W.B.
Sprint
Eight
Il & Part
(AllI,I &
fvlks.
servo no.
64949077
assemblies
(LE72696)
& Coupe Morris
64949000
Triumph
Triumph
&CA,
(excluding
11, Oxford
IIIIIIHC,
Austin/Morris
r-1::>rris TR4
1600
Toledo
TR3
IV
r-linor
& "Farina"
Spitfire
GT6,
JC PC
Mks.
&(All
& TR4A
Mks.
Vans
GT. I, MG
Saloon
1100, II
Vehicle application
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ho;izo.,:a;
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'Fig.2
 Slave cylinder Hydraulic slave cylinder
outlet port assembly

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Slave cylinder

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inlet {:.=============== = ;:== __ 1

Fig.3

IMPORTANT:
FIT IN LINE NON-RETURN VALVE TO HOSE WITH THE Single line
Position of In line non-retl.:rn ARROW POI~HING TOWARDS THE SERVO b~ai<emaster cylinder

r:
va:'/e (if fitted) .
(I If' L\;:J tlOT SUPPLIED]

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To front
, New I brakes
feed pipe 1- Remo';e existing
brc'<= pipe

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,I 3-way
Ir,liet
adaptor :--~.-
r.1a:1!fold
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New
SJ;Jply pipe

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To rear
brakes

Alternative hydraulic
fittings

FigA Schematic layout of, brake servo unit and

relative co'mponents .