Hurry up......we're waiting. Vaccuum the disc out, glue it on, put it back together and tell everyone how damned smart we are. It's a one hour job! :stupid::stupid:

Removing the booster is not difficult. Be sure to adjust your master cylinder rod to correct depth once you have the disk back on. Adjustment procedure is in the FSM.

Diseazd, Sorry to say your vacuum idea did not work for me. I will tell you why. I have removed the booster and I find that there is not a disk in there. Only thing I can think is that the PO for some reason some how lost it. If anyone looking at this thread has a used disk I would buy it. I know that Blue says to cut one and I will if I can't find a used one.

Sorry to hear that jcb. What I would do if I were you is to buy an old worthless booster on EBay.......pull out the plunger and scavenge the disc. Old boosters can be had for very little cash. You can get them from a 240 or 280. A junk yard or salvage site might also be a good place to look.

Edited March 9, 201411 yr by Diseazd

Looks like I will need to cut a disk out of some rubber. It would help me greatly if someone out there can tell me how hard the disk should be. Pictures look like it is hard rubber with no "give" to it. Any advice?? thanks JB

Yes it is hard rubber,,, try a mud flap from an 18 wheeler truck or similar.

It is possible that the reaction disk is still in the center barrel of the booster (where it should be)... have a good look in.

Philip

I was convinced mine was lost too as no kind of shaking produced a rattle inside. Luckily enough, I was able to reach in with a finger, dislodge it from the inside of the housing, and finally shake it out.

In other words, the disk was stuck to the inside of the booster housing and shaking didn't get it loose until I manually loosened.

Leon, I thought it had to be in there also but so far nothing. I tried reaching in with my finger but could not feel anything. I tried a bent coat hanger but got nothing. I am going to try to cut one. How thick and how hard do you think the rubber for the disk should be?? Any estimate is better than what I know about the thing as I have never seen one. Thanks for the reply and any info you have about the disk. JB

Here you go: http://www.classiczcars.com/forums/wheels-tires-brakes-s30/17972-reaction-disk-lost-booster.html

As a precaution, I glued the disk onto the piston in the booster once I'd fished it out.

As far as hardness, I'm sure you can substitute polyurethane or polyethylene and be fine. You can find some round plastic stock (and probably rubber for that matter) on mcmaster.com and cut it out if you can't find the disk in your booster.

Edited March 10, 201411 yr by LeonV

For example: McMaster-Carr

Thanks Leon, I am going to make sure it's not in there. Hopefully I can find it but if not I feel ok with cutting a new one. Thanks again, JB

Sure thing. If you can't find it, I wouldn't hesitate to cut out a PE, PU, or Buna-N rubber disk and stick it in there. Just remember to glue it in place and adjust the master cylinder push-rod to spec.