Hi guys and girls, I need a little help with a 2002 TD5, 70,000 miles, the car had regular use but only short runs and would often stand for days in between. It is LHD but I do not think this adds any complication, no warning lights on the dashboard. ABS works fine, car stops in a straight line.
Some history to help with diagnosis:
Brake pads front and rear have plenty of material and are contacting the brake discs evenly.
The wheel bearings have no play so this is not pad 'knock off'.
No leaks anywhere and fluid does not fall
No leaks in the vaccum system
About a year ago the owner complained to his mechanic that the brake pedal was travelling and that a 'double pump' brought the pedal up and all was OK until the brakes were needed again a few miles later down the road and the travel reappeared. His mechanic bled the brakes and this did not really improve it and then the mechanic shyed away saying he was not sure ect. The owner took the car to 2 spanish garages and they both shrugged there shoulders so he quickly left. I then come on the scene and with the engine running and a hard pressure on the brake pedal the pedal holds steady, ease up on the pressure and the pedal falls slowly towards the floor but not quite reaching it. I suspected the master cylinder but bled the system anyway and this changed nothing, I bled from the furthest wheel working towards the master cylinder and with the engine running.
The fluid was black before I started bleeding further adding credence to my suggestion that the master was toast. We purchased a new one and fitted and bled the system it was perfect! Until he drove about 60 miles and the brakes came on by themselves and slow but sure he was brought to a stop. Now I have seen this before and would normally indicate the brake servo has been badly adjusted, I went on the call out and shimmed the master away from the servo by using a couple of thin washers and all was well. A few day laters I removed the master and wound in the adjuster one and a half turns and the pedal has some travel but no more 'auto active' brakes. Futher enquiries reveal that the previous mechanic had wound out the servo pushrod to bring up the pedal!
Now before I go removing the master for the second time adjusting the rod out a little bit again perhaps half a turn and rebleeding ect I need to know three things:
1, is there any other bleed nipples on the TD5 other than one on each wheel?
2, is there a known measurement for the servo pushrod?
3, Am I missing something completely here and just being plain thick?
Thanks for anything you can offer guys.
regards
Dave
Some history to help with diagnosis:
Brake pads front and rear have plenty of material and are contacting the brake discs evenly.
The wheel bearings have no play so this is not pad 'knock off'.
No leaks anywhere and fluid does not fall
No leaks in the vaccum system
About a year ago the owner complained to his mechanic that the brake pedal was travelling and that a 'double pump' brought the pedal up and all was OK until the brakes were needed again a few miles later down the road and the travel reappeared. His mechanic bled the brakes and this did not really improve it and then the mechanic shyed away saying he was not sure ect. The owner took the car to 2 spanish garages and they both shrugged there shoulders so he quickly left. I then come on the scene and with the engine running and a hard pressure on the brake pedal the pedal holds steady, ease up on the pressure and the pedal falls slowly towards the floor but not quite reaching it. I suspected the master cylinder but bled the system anyway and this changed nothing, I bled from the furthest wheel working towards the master cylinder and with the engine running.
The fluid was black before I started bleeding further adding credence to my suggestion that the master was toast. We purchased a new one and fitted and bled the system it was perfect! Until he drove about 60 miles and the brakes came on by themselves and slow but sure he was brought to a stop. Now I have seen this before and would normally indicate the brake servo has been badly adjusted, I went on the call out and shimmed the master away from the servo by using a couple of thin washers and all was well. A few day laters I removed the master and wound in the adjuster one and a half turns and the pedal has some travel but no more 'auto active' brakes. Futher enquiries reveal that the previous mechanic had wound out the servo pushrod to bring up the pedal!
Now before I go removing the master for the second time adjusting the rod out a little bit again perhaps half a turn and rebleeding ect I need to know three things:
1, is there any other bleed nipples on the TD5 other than one on each wheel?
2, is there a known measurement for the servo pushrod?
3, Am I missing something completely here and just being plain thick?
Thanks for anything you can offer guys.
regards
Dave
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