Have you checked out the vacuum pump?  A torn diaphragm can allow oil into
the booster, destroying it.  It would cause the symptoms as you describe.
The rebuild kit is cheap and not too difficult.  A disposable fuel filter
added in the vacuum line will reveal oil in the system.  Booster can be
tested simply with a Mity-Vac or other vacuum tester.

I made a homebuilt tool to start the impossible-to-reach nut out of a piece
of copper tubing long enough to reach in and a short piece of rubber hose on
the end of the tubing to grip the nut.

Greg Fiorentino
'85 300SD
'80 240D 4 spd. manual
'79 300DT (with new crate engine)
'95 and '97 Crown Vics

-----Original Message-----
From: mercedes-boun...@okiebenz.com [mailto:mercedes-boun...@okiebenz.com]
On Behalf Of Rich Thomas
Sent: Saturday, March 07, 2009 3:39 PM
To: Mercedes Discussion List
Subject: [MBZ] I am stupid

So about a year ago I put a ("new") used brake booster on the 300TD 
after spending a lot of time chasing a no-brake-boost problem, and 
finally decided it was the brake booster after huge amounts of effort on 
that.  Put on a new one and it was fine.  So a few weeks ago same 
problem, and no shutoff, I figured the used booster I put on had crapped 
out too.  Ordered one from the list mom, put it on last weekend, still 
no brake boost.  sh*t.  So today I put the previous one back on and 
started chasing vac problems again with the vac meter, and by isolating 
things it seems to be related to the lock system (they have never really 
worked) or something else not very critical, maybe in the HVAC system 
(which is not working either for some time.  I plugged off one tee going 
to the locks, have a bit better vac now but still not what it should be, 
and the car will shut off when I rev it a bit.  Brakes seem to be OK, 
but I gotta bleed them now, again.

So Occam's razor proves correct once again, I should have taken a look 
at that first.  But I am really good now at changing brake boosters and 
master cylinders, in particular that last nut way up under the pedal 
bracket that you have to contort to get at.

--R

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