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#Post#: 86845--------------------------------------------------
Fitting a series servo to a defender pedal tower
By: samc88 Date: April 1, 2014, 4:14 pm
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When rebuilding my series 3 it was decided to upgrade the
braking system to a servo assist. Its a 12J engine so already
has the vacuum pump on the engine to drive the servo.
Now, series 3 pedal towers are rare as hens teeth to get hold of
so I ended up getting one off a 110 which is a straight bolt on
replacement for the series item but there were a few problems
with the servo itself
a) the defender servo was way too big, there was no way at all
it would clear the bonnet
b) We found a disco servo fits the tower but the reservoir on
the cylinder is still too tall for the bonnet and as the master
cylinder and servo had been outside for the best part of a year
in the open we decided to get a series servo and master
cylinder.
c) a series servo will bolt straight to the pedal tower, however
the pedal itself needs modification and you still need to make a
separate feed from the reservoir.
This post will just be basically how we got a series servo and
master cylinder assembly to fit onto a defender brake pedal
tower
1) When the servo is fitted to the tower as is, the pedal sits
just a bit too far back so you wont get the full pedal travel.
Thats not the main problem however, you may notice that both the
servo and the pedal have a plate with a hole in and one of them
needs to be a fork to fit the servo properly.
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/PA051748_zpsb4a42ddd.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/PA051748_zpsb4a42ddd.jpg[/img][/URL]
2) The tower was disassembled to get the pedal out. (the sharp
eyed amongst you may notice that its the original series pedal
welded on to the defender one, this is just to make it look
better so it matches the other pedals :) )
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/PA051749_zps4da1803d.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/PA051749_zps4da1803d.jpg[/img][/URL]
3) A Plate with a hole in is welded either side of the pedal to
make a fork
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/PA051750_zps5da408b3.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/PA051750_zps5da408b3.jpg[/img][/URL]
4) this photo shows how the servo end fits inside the fork. A
pin with a hole in the end for a split pin goes through the
holes in the fork and servo fitting
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/PA051751_zps9bd39637.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/PA051751_zps9bd39637.jpg[/img][/URL]
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/PA051752_zpsb24b87b4.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/PA051752_zpsb24b87b4.jpg[/img][/URL]
and a photo showing the series pedal on the end once painted
black
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/PA051754_zpsae3e5dc2.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/PA051754_zpsae3e5dc2.jpg[/img][/URL]
5) The tower can be reassembled with the pedal and the servo was
then bolted to it
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/PA051755_zpsbe198fbf.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/PA051755_zpsbe198fbf.jpg[/img][/URL]
6) Master cylinder was bolted on and we found that although its
a series servo, as its on a defender brake tower the wing still
needs a bit of trimming for it to fit. This was carefully done
with the grinder
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/PA061757_zps18af62e2.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/PA061757_zps18af62e2.jpg[/img][/URL]
7) As mentioned previously, the reservoir bottle still sits too
high for the bonnet to clear. If you open the top of the
reservoir on the new cylinder you will see a threaded pipe
fitting which will need a 17mm spanner to remove. We got a pipe
fitting with a thread one end and on the other end a fitting for
a rubber hose to fit on to go in the threaded hole where the
reservoir once sat. As the original reservoir bottle had a
rubber hose fitting on it, this was cleaned and brough back into
service by bolting it to the bracket by the clutch cylinder
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/PA061758_zpsa3f34b61.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/PA061758_zpsa3f34b61.jpg[/img][/URL]
8) the defender pedal tower does have a slight angled bit at the
top which we thought was fine but when we tested the bonnet fit,
we found it to be catching the bonnet, making it unable to sit
properly. a dust sheet was put over the engine bay and this was
cut off with the grinder
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/PA061759_zpsd8857959.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/PA061759_zpsd8857959.jpg[/img][/URL]
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