Fitting a Redbooster Clutch Servo kit to an TD5 Landrover Defender

Published on Tuesday 08 November 2011
Categories: Land Rover | Projects |

The clutch pedal on my Defender is very heavy and causes a lot of pain with my knee problems. After seeing several recommendations for a clutch servo kit online, I ordered a Redbooster kit from www.redbooster.com who are based in Sir Lanka.

The owner of the business called me personally after I placed the order and offered to assist in any way with the fitting but the provided instructions are very good and we got the new clutch servo kit fitted in a few hours. The actual fitting of the kit was very straightforward, just had a few problems bleeding the clutch which was solved by using a power bleeding kit.

After fitting, the clutch pedal is very light and I had to add an additional return spring to the pedal so it offers some resistance to your foot.

Installing the kit

The kit came in a well padded box and with very comprehensive instructions with photos. There are also photos on the companies website which you can download and print.

The photos below show the different stages of installing the clutch servo kit.

The brackets and plumbing in the kit

The brackets and plumbing

[more]

The redbooster clutch servo with mounting bracket fitted.

redbooster clutch servo

The Vacuum reservoir and hoses which mounts under the wing.

Vacuum reservoir

Old clutch system in place.

Old clutch system

Old clutch master cylinder removed and top cover on the clutch pedal box.

Old clutch master

Top view of the new mounting bracket fitted with linkages to pedal box

new mounting bracket

The new mounting bracket fitted looking towards the bulkhead

new mounting bracket fitted

Clutch servo fitted, ready for hoses

Clutch servo fitted

Vacuum reservoir fitted below the wing, photo taken though the top plastic vent

Vacuum reservoir fitted

Vacuum hoses connected and ready to add clutch fluid and bleed the system

Vacuum hoses connected

Bleeding the clutch system

After the new clutch servo was fitted and the new hydraulic pipes all connected, we filled the clutch master cylinder with Dot 4 fluid and tried to bleed the system by pushing the pedal and opening and closing the bleed nipple on the slave cylinder. This didn't work so we used a power bleeding kit which is supposed to be used on a spare tyre to provide pressure. As we have an airbrush kit which runs from a diving bottle, we used this as it allows very good control over airflow and the pressure is regulated at 20 psi to force the brake/clutch fluid though the new pipes and cylinders.

Diving bottle and pressure bleeding kit setup

Diving bottle and pressure bleeding kit

The diving bottle and regulator which was set at 20psi to push the fluid into the system

push the fluid into the system

Bleeding the clutch complete

Bleeding the clutch

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5 Comments


Nikolas Karaoli

01 February 2019 at 6:14 pm

Hi i am interesting for red booster for defender td5 2001 right hand site . i want to inform you that the car belongs to company , i want to ask if you can send me other link for payment without vat .
company name : (removed private information)
am waiting for your reply .
thanks
best regards
Nikolas Karaoli

Brian

01 February 2019 at 6:17 pm

Nikolas, you will need to contact http://www.redbooster.com/ who sell the Redbooster system

Max

17 January 2020 at 10:34 pm

I want to know if is possible to install the red booster in my Defender Left hand Side?

Brian

18 January 2020 at 10:36 am

Max, I think the redbooster can be installed on the left or right side.

Matthew

04 March 2021 at 8:02 pm

Hey Brian, thanks for the instructions. Did you find that this helped with knee pain? I am facing the same issue and just ordered the booster as my last resort. Do you find it much easier on you knee or did it make a minimal difference?

Thanks!


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Brian Dorey

Welcome to my blog, here you will find my projects and other things.
I make websites and manufacturer and sell expansion boards for the Raspberry Pi range of computers.

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