Brake Booster in-car seal replacement, question for Oragex

[firstv70volvo]

After almost 20 years (2001 V70 with a Dec 00 build date) and 207K my brake booster seal is beginning to leak. I've found Oragex's Youtube video on replacing this seal with the brake booster in the car and can't say how much I appreciate Oragex making this video and many others. As much as I don't like working under the dash of the car I'm going to attempt this because I don't want to pull out the brake booster. Seal is on order and I'll post an update when job is completed.

The question I have for Oragex is how is he able to get both hands up into the space to install the seal? I've crawled under the dash and I can only get one hand up there at a time, what's the secret position to get both hands up near the seal? He not only gets both hands up there he's got a great camera angle, good lighting and a high resolution video being produced at the same time. Amazingly good video and very informative on the steps needed to get the seal installed.

[firstv70volvo]

The other day I attempted to replace the leaking brake booster seal in the car as shown in the Oragex Youtube video, which is excellent. Even with the detailed instructions and tips I was still unsuccessful as I cut the seal during the install. I almost had the seal lip fully tucked in but as I pressed on the seal to insert the final part of the seal edge the seal tore. Ended up replacing the brake booster with a remanufacture one but now that I have the original booster on the workbench I think I know what happened. The edge of the brake booster where the seal is inserted is pretty sharp so you cannot apply too much pressure on the seal when the seal lip is partially inserted, the seal lip still outside the opening is sitting against the edge of the booster opening and too much pressure tears the seal. You have to apply some pressure to get the lip inserted and near the end when most of the lip is tucked in the pressure needed increases but too much will cut the seal. This is a tough seal to install and even more difficult working under the dash but can be done as shown by Oragex and I think I would be successful on a second try but needed the car and couldn't get another seal in time to try.

[oragex]

Just seen this topic, sorry about the misfortune. As I tried to mention in the video, it is the kind of job that needs some sort of mind control to succeed and good fingers perhaps (I used to play piano ) Anyhow, I see what happened with the seal and that is precisely the difficult point due to the seal edge making an 'outer' angle, the opposite of what would actually be needed for an easy install - it's this angle that will actually keep the seal in place once installed. The use of that side pushing 'tool' being essential to force this edge in, I feel sorry I couldn't present more details about it. And that had to be combined with pushing the plunger to the opposite side to increase the gap. Perhaps I should have also added some footage with the work done on a booster on the bench, for better understanding. I know some people in the comments managed to install the seal, while others couldn't do it - some also tried the 'red' seal from Poland without success. As for reaching with both hands perhaps it's a matter of shoulder flexibility.

[firstv70volvo]

Just seen this topic, sorry about the misfortune. As I tried to mention in the video, it is the kind of job that needs some sort of mind control to succeed and good fingers perhaps (I used to play piano ) Anyhow, I see what happened with the seal and that is precisely the difficult point due to the seal edge making an 'outer' angle, the opposite of what would actually be needed for an easy install - it's this angle that will actually keep the seal in place once installed. The use of that side pushing 'tool' being essential to force this edge in, I feel sorry I couldn't present more details about it. And that had to be combined with pushing the plunger to the opposite side to increase the gap. Perhaps I should have also added some footage with the work done on a booster on the bench, for better understanding. I know some people in the comments managed to install the seal, while others couldn't do it - some also tried the 'red' seal from Poland without success. As for reaching with both hands perhaps it's a matter of shoulder flexibility.

You presented a great deal of details, it's just a tough seal to install from under the dash. I was very close and at one point I had thought the seal lip was inserted all the way around and ready to press on the rest of the way. Part of it must have still have been outside the opening and then when I pressed on the seal to seat it all the way I cut the seal. The metal edge of the opening is a pretty sharp edge. Even installing the seal on the bench requires just enough pressure for the seal lip to insert into the opening and stay inserted while working it around completely. Too much pressure will damage the seal so it's a little tricky. I used the old seal to practice with and I did get better at it. I had made a good tool to press on the edge so that wasn't a problem just my eyesight and not seeing the seal completely inserted all the way around.
The other "tool" I made out of scrap wood for the job was an under-the-dash-save-your-back platform and this was inspired from back pain memories the last time I worked under the dash to install new heater core o-rings. It worked pretty well.

[abscate]

That backboard is awesome,well done

[oragex]

That backboard is awesome,well done

Yep, really helps for that body posture

[SVO LOU]

This single seal is what you need to stop the hissing sound?
I've lived with it for almost 2 years because I thought you needed the booster assembly so I wrapped Saran wrap around that long accordion seal.
No joke.
Suffice it to say I'll be ordering one of these soon.

[gnalan]

I need a backboard like that. All the different cars I've had, and all the twisting upside down to reach something under the dash, I'm surprised I didn't think of making something like that.

[firstv70volvo]

Just seen this topic, sorry about the misfortune. As I tried to mention in the video, it is the kind of job that needs some sort of mind control to succeed and good fingers perhaps (I used to play piano ) Anyhow, I see what happened with the seal and that is precisely the difficult point due to the seal edge making an 'outer' angle, the opposite of what would actually be needed for an easy install - it's this angle that will actually keep the seal in place once installed. The use of that side pushing 'tool' being essential to force this edge in, I feel sorry I couldn't present more details about it. And that had to be combined with pushing the plunger to the opposite side to increase the gap. Perhaps I should have also added some footage with the work done on a booster on the bench, for better understanding. I know some people in the comments managed to install the seal, while others couldn't do it - some also tried the 'red' seal from Poland without success. As for reaching with both hands perhaps it's a matter of shoulder flexibility.

Just found out today from URO (APA Industries) that the brake booster seal they sell is not compatible with every seal used in the ATE brake booster for Volvo model years such as mine. After buying two of their seals and having problems(damaging) installing both of them, once in the car and once on the bench I find out the original seal in my brake booster is not compatible the seal they sell. Even though I purchased the seals from two different places and after entering my car model, year and trim to filter which part to buy the seals wasn't the correct one for the OEM original ATE brake booster in my car. They do note the seal number their seal replaces but I didn't realize there are more than one seal types used in my Volvo. Very frustrating, a lot of work and lot of expense wasted on this effort. I also noticed in the comments of your video that other people just weren't able to successfully install this seal no matter what they did and I'm thinking they had brake boosters/seal not compatible with the one URO sells.

If anyone else is considering doing this seal replacement please be warned you'd better get the number of the original seal and compare with the URO seal replaces or else you'll waste all the time and expense I did. This is the ATE seal 03.7718-5028.1 that their seal replaces, if your original seal number is not this then you've been warned and good luck reading this number off the seal with the brake booster in the car.

[oragex]

Good information. I did update this in the video description. So the only way to be sure what to order is to read your old seal ? That would mean you have to first remove it from there, before ordering, which is quite inconvenient.