Brake servo pipe replacement on Mk2 1.9 PD TDI

[insanitybeard]

Greetings all, in case anybody out there has the issue of a hard brake pedal on the Mk2 1.9 PD diesel (common issue with the brake servo pipe splitting), the Ford part number for the replacement servo vacuum feed pipe is 1357764 and at time of writing one Ford dealer on is selling them for about fifty quid. Recently had to change mine, my symptoms were that the pedal seemed ok on the first pump of the pedal (as the vacuum had a chance to build up) but when released and reapplied quickly the pedal would become hard and the brakes less responsive- dangerously so if you are caught unawares by this when expecting the usual brake response!

The new pipe is helpfully NOT supplied with the green blanking cap that blanks off one of the small bore vacuum pipe tees (visible behind the fuel filter in the below image), so you'll need to swap it over or buy a new one if it's knackered (although you could easily plug it with something else). My old pipe had split at the brake servo end, interestingly when fitting the new pipe I noted that it (the new pipe) didn't line up perfectly with the angled sealing grommet on the servo itself so I wonder if the pipe not sitting 'naturally' and being stressed due to not being quite the right shape is the reason for the failure in the first place.

The pipe can be replaced from up top without needing to go underneath or drop the undertray but you do need to remove the aluminium heatshield behind the inlet manifold that covers the boost control valves, and also the short 90 degree rubber boost pipe connecting the EGR valve to the rigid plastic pipe that houses the MAP sensor to the left of the fuel filter when looking into the engine bay.

As well as fixing the hard brake issue, replacing this pipe also made the engine smoother at shut down. I had noticed it becoming more juddery when switching the engine off and had feared this could have been related to the dual mass flywheel on its way out but infact must simply have been due to the weak vacuum meaning that the anti-shudder flap inside the EGR valve housing wasn't actuating properly when the engine was turned off.


[attachimg=1]
^non-return valve on servo pipe with the green blanking cap that isn't supplied with the new pipe (boost pipe removed for access). Note that the nylon tubing can be seen starting to split either side of the non-return valve where it's swelled over the non return valve spigots at manufacture.


[attachimg=2]
^New pipe (actually the old one after removal). Servo end bottom left, vacuum pump end top right.


[attachimg=3]
^Close up highlighting the large split in the nylon tube at the servo connection. Again, the split has occurred where the tubing is swelled over the spigot of the servo connection at manufacture.

[brianh]

Nice writeup - though I would also mention that you can replace the spilt piece of pipe with some silicon vacuum hose (reuse the original ends where the units connect to the bit you've shown in the photos). Much cheaper than the Ã,£53.17 I'm seeing for the original part using your part number in the photo. It also affects the petrol models, though the pipe is a different length on them, they have the same failure points. Typically seen on the petrols as poor brake assistance and rich running (smelly exhaust).

[insanitybeard]

It's a fair point, no reason why you can't use some flexible vacuum hose for a cheaper repair if you can find some the right diameter to fit the end connections and the non-return valve. A quick measure of the servo end spigot suggests the hose would need to be approx. 10-12mm internal diameter.

[brianh]

I sourced mine from Ebay, can't remember the size offhand but it did the job on the mk1, and the same hose was still usable when I had the same issue on the mk2. Petrol hose size may be different to the diesel ones, If i get round to checking I will post the size for reference.

[daddyfixit]

I sourced mine from Ebay, can't remember the size offhand but it did the job on the mk1, and the same hose was still usable when I had the same issue on the mk2. Petrol hose size may be different to the diesel ones, If i get round to checking I will post the size for reference.

Hello Brian, did you measure that servo pipe at all?

[JR Watchet]

If not too late, had same problem on a 2005 model - it was splitting where the vacuum pipe fitted onto the servo - could be reached from top of engine bay (air box out is easier) - all I did was get a large volume of a quick sealing silicon and surrounded the pipe and the end fitting with a great blob of it and left 48 hours to fully cure.   Worked a treat!

Eventually bought a replacement pipe from a parts dealer (not main dealer) but was a b****d to fit as several connections and needs to be done from underneath on a ramp.

Good luck

[daddyfixit]

If not too late, had same problem on a 2005 model - it was splitting where the vacuum pipe fitted onto the servo - could be reached from top of engine bay (air box out is easier) - all I did was get a large volume of a quick sealing silicon and surrounded the pipe and the end fitting with a great blob of it and left 48 hours to fully cure.   Worked a treat!

Eventually bought a replacement pipe from a parts dealer (not main dealer) but was a b****d to fit as several connections and needs to be done from underneath on a ramp.

Good luck

I had planned to do this on Boxing day; the pipe, pollen/air & diesel filters while the surfboard was out,  so thanks for the tip !!

[daddyfixit]

I had planned to do this on Boxing day; the pipe, pollen/air & diesel filters while the surfboard was out,  so thanks for the tip !!

it got worse;   hissing noise at brake pedal-goes if you tap pedal gently...driving before and pedal went rock hard, no servo at all !!     2 mins later all ok again...so, Monday I'm getting a servo replacement for it. 


bummer

[daddyfixit]

update; After a few delays at garage, its actually getting the servo fitted today: I just rang for an update & was asked "how many people said no to this job ?".  Apparently its an arsehole of a job to get at under the dashboard plus using the special tool to release brake pedal white clip.   has anybody else swapped a servo on a Galaxy at all, as I feel guilty for giving my mate the job now ?