[s-cars] X-Plug question

[Fred Munro]

John;

I didn't have to remove the banjo fitting to remove my x-plug - your car may
be different depending on the position of the line from the banjo bolt.

Make sure you pump the brakes until the pedal gets hard (at least 50 times)
to discharge the pressure in the brake boost accumulator (AKA the bomb). The
x-plug (and the banjo bolt beside it) are on the brake boost circuit and
opening the plug with 2000 psig stored in the bomb would be a really bad
idea.

You do use a drag link socket (looks like a large flathead screwdriver tip
that takes a 3/8" drive) - mine is a Gray T27 and is a perfect fit to the
x-plug.

When I changed my x-plug O-ring the hydraulic pump lost it's prime and
wouldn't pressurize the brake circuit. I had to bleed the pump. I made sure
the pressure was discharged and loosened the bolt on the banjo fitting. I
idled the engine until the oil came out of the fitting, shut off the engine,
and tightened the banjo bolt. I've had to do this both times I've had the
x-plug out.

NOTE: this circuit on the pump is high pressure, low volume. If you bleed it
this way make sure the banjo fitting bolt is backed WAY out, giving the oil
lots of room to exit. If you restrict the opening, you'll get a (very messy,
potentially dangerous) high pressure spray. If you try to tighten the bolt
with the engine running you'll get the spray AND blow the o-ring seals on
the banjo fitting.

Wear eye protection when you are fooling around with this along with any
other safety gear you feel necessary.

HTH

Fred Munro
'94 S4


-----Original Message-----
From: s-car-list-bounces at audifans.com
[mailto:s-car-list-bounces at audifans.com]On Behalf Of
jpb3wvu at frontiernet.net
Sent: June 25, 2004 11:20 AM
To: s-car-list at audifans.com
Subject: [s-cars] X-Plug question


My X-Plug is leaking and I just picked up the replacement plug and
O-ring from the dealer.  Any BTDT on the removal of old plug and
installation of new?    It looks as thought the top banjo bolt will
need to be removed to get the plug out.  What do you wrench the plug
with?  Large flat screwdriver?  i have searched the audiworld forum and
found that a "drag link" socket is mentioned.  WTH is it and does
anyone have a part # or description I can use at my FLAPS?  thanks.

john

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