[urq] Brake servo overhaul

[Eric Renneisen]

Hoping to fix both the hemorrhaging brake booster and replace the leaky
proportioning valve, I dove under the hood this evening.  For the
booster, I was armed with Sean's instructions
(http://www.quattro.ca/Urq/Brake_servo_guide.pdf) and a seal kit from
Sport Wheels.

Things went great until the very end.  I had cleaned everything and put
on all the new o-rings.  The final piece was the tiny oil seal in the
end of the plastic cap.  While pressing the old seal out, the cap broke.
See results here:
http://home.comcast.net/~racingiron/booster1.jpg
http://home.comcast.net/~racingiron/booster2.jpg
The seal is a tight fit, and getting it past the tapered end of the cap
took too much force.  Even if it hadn't broken, I'm not sure if the new
one would've gone in cleanly.  Maybe the freezer trick would've done it?
Anyone got any BTDT tips for R&R of this thing?

The cap has an Ate number on it, but I'm not expecting to be able to
find a replacement.  I don't really feel good about spending $500 on a
new servo.  Does anyone have an old booster they'd like to get rid of?
I'd prefer an aluminum one so I can use the same seal kit I've already
got, but I really just need an identical end cap (provided I can replace
the seal without breaking it again).

After finishing my stream of obscenities I was in no mood to replace the
prop valve.  I was really looking forward to getting her back on the
road...

Eric Renneisen
'93 S4
'90 CQ 20V
'86 garage art
'85 urq
Chattanooga, TN