Brakes - Brake Pedal Return Spring Noises

Boxster
3/00
4605

Binder - 4, Running Gear

7-21-00

Brake Pedal Noise

Vehicle Type:
Boxster/Boxster S

Model Year:
As of 1998 (W)

Concern:
Noise in brake pedal

Information:
When the brake pedal is depressed, noises may be generated by the return spring. To eliminate the noise, a bushing is installed in the spring eyelet hole of the brake pedal. The bushing was installed in production as of 10-15-1999, from vehicle identification numbers (VIN) 98 OYU 62 2455 and 98 3YU 66 0288. In case of noises on earlier vehicles, a bushing can be retrofitted.

Parts Information:

Part Number Description
996 423 243 00 Bushing

Tools:

Hand held drill or drill press Drill bit - 7.5 and 9.5 mm
Adjustable pliers Support for use with the drill press
Small hammer (wood block min. 19 mm thick)

Work Procedure:

1. Remove the brake pedal.





2. If using a drill press, position the support point for the brake push rod on the support block (figure 1). For drilling with a handheld drill, clamp the support point for the brake push rod in a vice with soft vice caps.

3. Drill out the eyelet for the return spring with a 7.5 mm drill bit (figure 1). Countersink the bore on both sides with a 9.5 mm drill bit.





4. Place the bushing on the bore by hand from the left side on the pedal (figure 2) and press approx. 3/4 of the length of the bushing into the eyelet with adjustable pliers. Finish by pressing the bushing in using your hand or a small hammer as far as it will go.

5. Reinstall the brake pedal.

Working Time:





Literature:
Boxster Technical Manual, Group 4:
46 05 19 06 - Removing and installing the brake pedal Technical Bulletin number 3/98 - Brake and clutch noise





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