Soft Unresponsive Brakes!

[Obadiah]

Hey Guys And Gals

 

This is for information purposes. I have just fitted an new Vacuum Hose to my 2001 1.9TDi Gal and the effectiveness of the brakes has gone from unresponsive to "Ouch My FACE!!!"

 

A little history of the problem.

 

My wife reported that the brakes were really wooly and unresponsive when she was driving through the country lanes slowly. it was to the point where she had nearly had accidents as the Gal just didn't want to stop.

 

The front disks were indicating signs of warping through the steering wheel, so i bought new disks and pads. This had absolutely no effect on the braking at slow speeds, despite using racing grade cryogenically frozen eight grove disks on the front and standard racing disks on the rear.

 

Next I decided to have the brake fluid completely drained, flushed and replaced. Again this had no effect. I started to look at the Master Brake Cylinder with the directions found on this site, but that proved to be operating correctly.

 

Someone finally mentioned that the brakes needed a vacuum hose to operate. If this had split or cracked the vacuum would not be drawn to the required magnitude when the car was travelling at slow speeds.

 

I have included some photos to try and direct you as much as possible. The rubber vacuum hose should be partially pliable, also the connection to the vacuum pump is supposed to be soft rubber, not solid like mine was.

 

I can't recommend enough that you have a look at your Gal's brakes!!!

 

Mk2 1.9 TDi 2001 Gal 

The Part number: F1357764

Services: TUBE - VACUUM

 

If the following photos don't work please use the following link: https://www.dropbox.com/sh/0s222yf75bowo47/d8LJdQBGKc

 

1. Location of Vacuum Pump

 

2. Location of Vacuum pump, vacuum hose situated behind fuel filter

 

3. Vacuum Hose connecting in to rear of vacuum pump

 

4. Old vacuum hose with Emission Control vacuum pipe branching off. NOTE!!! The green cap is NOT provided with the new hose under the above part number, ask for one separately as it is not easy to remove. The tape is covering some severe cracking as can be seen in the latter photos.

 

5. Vacuum Hose situated at rear of engine bay, adjacent to air con pipes and below the fuel pipe work.

 

6. Old vacuum hose connection to the Master Brake Cylinder. Situated at the rear of the engine, on the left hand side, below the brake fluid reservoir. NOTE! The engine bay partition must be removed to be able to see these components.

 

7. A more clear view of the above connection

 

8. New Vacuum Hose connected, YAY!  The connection to the Master Brake Cylinder is very tight. I don't recommend using any oils or greases on this as it is required to be tight for the vacuum to be drawn. I used a bit of water to lubricate the connection and a handle of a hammer to gently tap it in.

 

9. The new Vacuum Hose. Note the old green cap and the nice tight seal on both rubber pipes.

 

10. Old Vacuum Hose.

 

 

 

 

 

[seatkid]

Good post and well done. Just a couple of points, all VAG cars use these rigid plastic servo pipes and its very common for them to split at the ends causing loss of vacuum. Loss of vacuum means loss of brake assistance so the pedal will go hard (not soft) and you have to push VERY hard to acheive the same brake effort. You may also experience engine performance problems as the turbo and egr systems are reliant on the same vacuum delivery system - thats what those small pipes at the non return valves are for.

 

Where did you get the replacement parts from and how much did they cost?

 

One for the tech FAQ's I think

Edited September 21, 2013 by seatkid

[avee]

Thanks for that post Obadiah

I have similar symptoms

was just going to replace discs/pads

and bleed system.

I think I will check pipe first

do you have any part numbers etc

avee

[Obadiah]

Hi I've added the part number mid way down the post.

 

 

Mk2 1.9 TDi 2001 Gal 

The Part number: F1357764

Services: TUBE - VACUUM

 

Mine cost £31.99 before tax and delivery. Remember to ask for the green cap to block the spare feed off.

 

Hope this helps

Edited September 23, 2013 by Obadiah

[seatkid]

From a ford dealer?

[Obadiah]

From Vospers Ford Dealership in marsh mills, Plymouth. They don't sell many so if you mention I bought one back in July and with the above number they should jump straight to it. Edited September 24, 2013 by Obadiah

[xavier]

Would it be worthwhile trying to wrap the ends in self-aligning rubber tape? This might effect a temporary (or possibly semi-permanent!) repair.

[Obadiah]

I take it your pipe is broken too. I wrapped the ends of mine in rubber amalgamating tape. This only helped a small amount as the whole pipe was pretty done for. The end that slides onto the vacuum pump is supposed to be soft rubber, mine was solid.

 

The choice is ultimately yours, I can only advise on what I did. Have you ordered the part yet?

[t-aslam]

Does anyone have a part no for the green cap? I can't seem to be able to convince my local TPS that it wasn't supplied with the hose and they are adamant it comes with the hose. I re used the old one but I don't feel it's blanking properly.