Installing a clutch booster is simple — if you follow the rules. At our production base in Chongqing, every booster is bench-tested before it ships, and the most common warranty claims we see come from avoidable installation errors: dirty lines, trapped air, or a misaligned push rod.
Here are the 8 installation rules from our production base — the same rules we hand to every distributor. Pass them on to your workshop customers and you will cut fitment complaints to near zero.
After removing the old unit, run the engine for a few minutes to purge the lines — debris, oil and water must be blown out before fitting the new booster. Dirty lines are the number one cause of poor clutch performance and shortened service life.
Recommended working fluid: DOT3 or DOT4 synthetic brake fluid.
The maximum stroke of the shift control valve is 32 mm. When installing, push the push rod inward at least 32 mm. At the 32 mm point the spring force is under 120 N; as you push further, the clamping force on the valve piston rises to about 400 N (max 600 N). For best performance we recommend pushing the rod in to about 40 mm.
Make sure all air is expelled from the oil pressure chamber during installation, or boost assist will be weak and inconsistent.
Drain the old brake fluid from the existing lines and refill with the fluid specified by the original vehicle manufacturer.
The ball head of the push rod must seat correctly in the socket of the release fork. A misaligned ball head causes abnormal wear and premature failure.
Install the booster with the bleed screw facing upward — this is critical for complete bleeding.
The angle between the push rod and the centre axis must be controlled within ±5°. Follow the vehicle’s service manual for routine maintenance.
⚠ Warning: never adjust or operate the booster while it is not mounted on its fixing bracket.
警告：助力器未安装在固定支架上不得进行调试和操纵。
Send us your OE part number (WG / DZ / 1608010 series) — we confirm the cross-reference within 24 hours, free of charge. You can also look it up online or download the full 44-number cross-reference catalog.
