Rubber plug,on firewall behind brake booster...
 

Does anyone know how to get it back in place? There are two, just under the fusebox. It is the smaller one of the two. The old string trick will seem to only work if you pull the string from the inside-easier said than done. Way up under the dash. :eek: I've also tried pushing on the center of the plug.

BTW-I had a small water leak in the cabin and started looking for the source. I found the plug out because someone had run a hot lead from the fusebox to one of those early mobile phones. The phone wires were rubbed bare as was the [green?] wire that belongs on the car. Anyone know what this heavy green wire goes to?

I did put liquid electric tape on the bare wire. ;) Thanks...

Cheers,

Bill

This is usually like doing a tire... you get a little corner put where you want it and then move in small increments from there...
Helps to have something thin but NOT SHARP to push on it with ... something like the tool used to tuck headliners and window gaskets in place..
ALSO may be very important to have sprayed the entire thing with silicone spray.... just as you use tire lube around the rim of the tire before you attempt to force it behind the rim edge...
And of course being sure you have the proper size for that hole makes a lot of difference....

I'm not replacing the plug--it is the original just hanging on the wire when I found it due to some mechanics neglect.

I did try what you suggested but the problem with that is there is not enough room around the brake booster side of the plug. I can get 2/3 in but not the part behind the booster. I would just silicone the part I can't get but want it in there right like the factory did. This is a nice ride and I want to keep it that way. I'll post pics one of these days.

Failed to mention in first post--'85 300td.

I may have used the wrong spelling on the spray....
I mean the stuff which would look like WD40 if sprayed on it... thin and clear... and just makes it really slippery...
NOT anything like RTV silicone gasket maker...

I used a dab of dish soap thinned with a little water on the inner lip. It's the dang brake booster. Makes it impossible to get to it.

I know the stuff you're talking about but I've had success in the past with the dish soap as I'm sure you have too.

Thanks :D

Cheers,

Bill

I also used a weak soap solution to lubricate the plug. The only tool I found that will do the job is perseverance. You'll eventually get it if you're patient.

Good luck with it (and don't give up).

Wes

Thanks Wes. I won't give up nor will I throw anything. :D

I'm back out to try again. I'll get it with a little help from my friends. Thanks all and I'll let ya know what goes.

cheers,

Bill

Brake Booster First
 

Bill try putting the part in first behind the brake booster ..just an idea...Jim

Get someone with small hands to try :) Or get under the dash, I was under mine last night, it's not bad to get to. (Was pulling out an old radar detector and its wiring.)

Funny you should say that. Only a woman would think of using my 10 year old son for such a project!

I did get it in but only to discover I still have a little water getting into the cabin. Started pouring at all the appropriate places and, sure enough, the after market windshield is leaking. If you look closely you can see the shadow where the gasket used to be and , in the corners at the bottom, the aluminum trim does not fit in the original groove due to the windshield being a little different shaped. Called the place and they said bring it tomorrow but I know what they're gonna do. Some rtv silicone and send me on my way. Forget that!! I'm going to get a real OEM this time and pay out the dough to make it right. Once again, this is a real nice ride. Under the floor mats the metal in the rear seat footwells it looks brand new. The tailgate has zero rust with the only rust being drivers front fender in the usual spot. :eek: Nice interior as well and even the cruise works.

Do not get glass from Diamond Auto Glass, a nationwide chain I believe. This is the second time I've had problems with their glass and from here on only oem for me please. ;)

Thanks all--

Bill