New Servo Rattling

Bought a new TRW servo and it's just arrived. I took it out the box to find something is moving around inside and causing it to clang like a bell.
I've messaged LRDirect to enquire about returning it. Pretty sure there's nothing much in them but the spring and the diaphragm?
Surely something moving about can't be right?

I feel for you, and it agree it needs to go .. either back to them or in the bin .. either way, it sounds kaput..

Not something daft like a loose fixing inside it?

Disco1BFG said:

I feel for you, and it agree it needs to go .. either back to them or in the bin .. either way, it sounds kaput..

Not something daft like a loose fixing inside it?

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No idea. Can't imagine there's much to come loose. I can't see anything moving through the big hole that the master cylinder bolts in to, so it must be the other side of the diaphragm. I've taken the temporary plug out of the non return valve hole, but nothing appears at the hole when I rotate the servo - it just clangs as something moves It's bloody annoying. I should have bought a Britpart one for a quarter of the price

Well, if there is nothing loose, …Back it goes then! And yes, try a BP one …

Disco1BFG said:

Well, if there is nothing loose, …Back it goes then! And yes, try a BP one …

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There's something rolling around a causing a boinging sound in there They've asked me to send a video, which I duly did, I await to see what they say next week

LRDirect have emailed me back and, having watched and listened to the video, have offered a refund or a replacement. I've asked them to send a replacement. They said to scrap the first one. Well done LR Direct

Al2O3 said:

LRDirect have emailed me back and, having watched and listened to the video, have offered a refund or a replacement. I've asked them to send a replacement. They said to scrap the first one. Well done LR Direct

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I would cut it open out of sheer curiosity to see what has failed

lynall said:

I would cut it open out of sheer curiosity to see what has failed

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That has crossed my mind. I know it's carped, but it'll be such a shame to cut up a £190, new, shiny thing

Al2O3 said:

That has crossed my mind. I know it's carped, but it'll be such a shame to cut up a £190, new, shiny thing

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Borrow a boroscope?

lynall said:

Borrow a boroscope?

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That's a bloody good idea! And, I've got one somewhere

Ooooh… waiting with interest to see what has “escaped”

and, good on LR direct too .

Disco1BFG said:

Ooooh… waiting with interest to see what has “escaped”

and, good on LR direct too .

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The results are in!
I could see nothing with the USB boroscope

So, I took the rubber vac tube grommet out to give me a bigger hole to see inside. Rolled the servo around to see if anything fell in front of the hole - Nothing! But plenty of clanging
Put finger in the hole for a feel about and discovered a flat, plate ring inside. It surrounds the master cylinder hole, but is shaped to fit the profile of the servo where it curves down to the wider diameter section. The ring is located on the two studs that come out of the servo. It's loose by about 5mm, so clonking back and forth on those studs


Fortunately, I'm no Rolf Harris, but can you get the picture
Maybe it's supposed to be reinforcing the pressed housing of the servo where the master cylinder bolts on?

The servo clang!

I'm glad you didn't get your finger stuck in the servo. That would have been a fun trip to the hospital, wouldn't it?

Brown said:

I'm glad you didn't get your finger stuck in the servo. That would have been a fun trip to the hospital, wouldn't it?

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Good job @Broke Again or @kurtjohnson10 weren't investigating it

Al2O3 said:

Good job @Broke Again or @kurtjohnson10 weren't investigating it

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We only rattle backdoors ffs

kurtjohnson10 said:

We only rattle backdoors ffs

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Tremendous

An interesting day!
New servo arrived this morning. Rattled and clanged like the first one Emailed LR Direct straight away to say it seemed very strange that I've got two that rattle. Were the suppliers really sure there was an issue with it when they listened to the video I sent? I also sent them my skilled artist's impression of the clanking plate and my theory that it was a loose reinforcement plate. I also asked if the supplier might be able to check a few more out and maybe compare a non TRW one.
LR Direct were very apologetic and said they would get straight on to the suppliers.
It didn't take long for them to reply and forwarded an email from the supplier, who had opened a few and they all clanked. They'd then tightened some nuts on to the studs and the clank stopped so it is a reinforcement plate that somehow tightens up when you tighten the master cylinder on. Those studs seem solid, so how they move I don't know.
I asked how to send one of the servos back and apologised for not realising it was meant to be that way. They replied saying there was no need to apologise and that the supplier did not want the servo back so I could keep it I replied saying I didn't feel comfortable with that and I offered to contribute to the postage. They thanked me for that, but said no and to keep it I'm not comfortable with that, so I'm going to offer it on LZ or put it on ebay and then give the money to the red squirrel conservation group I belong to, so we can buy a couple of trail cameras or some more traps.
If anyone reading this thread is interested feel free to PM me. It's a TRW servo part number LR013488G It cost £190.21 and came with a 2 year warranty, but you don't get that off me I'd be really happy with £100 for the squirrel group. Just over half price doesn't seem to bad to me. I haven't investigated postage yet, so I might have to add something depending on how much the postage works out at.

Top marks to LR Direct and their customer service guy, Nathan, who has been extremely helpful and supportive throughout.