Master Cylinder won't fit on Booster

[jimlrc5499]

I'm replacing the Brake Booster and Master Cylinder on my 2004 Ion. I have the correct parts. I verified that through three different suppliers using the vehicle's VIN number. The Booster went in fine, but, when I try to put the Master Cylinder on the holes on the cylinder won't line up with the studs on the Booster. Any ideas?

[pierrot]

Checking with RockAuto's catalog and an online GM OEM parts website I found that all IONs from '04, regardless of model type, utilized the same replacement part numbers. Since this is true then there are - in all likelihood - two possibilities which could be at the root of this problem as I see it: 1) a manufacturing error, or 2) a misboxed part.

Assuming that you still have the old parts can you measure the mounting set up of the master cylinders and the boosters for comparisons' sake? What are the brands and part numbers of the parts which were purchased?

[jimlrc5499]

I've since found out that the studs on remanufactured boosters tend to not be straight. I was advised to pull the booster and fit the master cylinder to the booster by bending the studs using a piece of pipe.

[pierrot]

If this were my concern I would take the new booster back to the parts store, show them the problem and ask that they straighten the master cylinder mounting studs on it. If you do that adjustment and damage the studs in some way then the booster will not be returnable. Candidly, I suspect that you will probably not damage the booster yourself if you are cautious. However, the point here is that one should to consider possible consequences if something goes awry. I hope that all goes well with the repair and it can be completed soon!

[jimlrc5499]

I was able to straighten the studs. I have the equipment at work to do it. If necessary I could have cut them off and replaced them. I had to wait quite a while for the booster and was going to have to wait more for a replacement.