1996 transit brake problem

[Luke]

ok it could be the servo - dont assume as you've replaced it there is no problem with it

you need to establish if the diaphram on the servo is split or one of the seals has gone

or is the issue with the vac pump not pumping enough vacuum for there to be any on it

[jamesallen3333]

Checked the back of the vacuum pump again and there is no suck at all now. The pump is new and a new gasket, I don't understand why its not working?

[Luke]

can you post a photo of it? someone might notice something a miss

[jamesallen3333]

I can try tomorrow when it's light (if it's still light by the time I get home) am tempted just to pull it off again and check the openings and gasket.

[gumgum traveler]

what about the hose between pump and servo [booster]might be blocked now pipe not new pump maybe full of oil

[jamesallen3333]

Right I think I've solved this problem and if I'm right, I am ashamed to say I have been a prize plonker.

I took the pump of again to check all the openings/everything seemed ok, so I undid the union nut where the pipe from the servo enters the pump and found a small plastic bearing blocking the inlet to the pump. """Please tell me that this should not be here"" I'm assuming it was in there for transportation to stop the ingress of dirt etc into the pump before installation. I road tested the van with the plastic bearing removed and it stops on a six pence.

Please can someone verify that the bearing should not be there. and if this is the case I would like to thank everyone that commented and thanks for your patience.

[Luke]

i dont know but i'd guess the small plastic bearing is part of the non return valve to hold the vacuum on the servo when the engine is switched off

[hiram23]

Posted the other day about a brake problem on 2003 ford transit. The brake pedal went hard on braking like a brick under the pedal, narrowly avoided an accident. after stopping the brakes returned to normal. the garage couldn't find a fault, checked the lot and road tested. The garage replaced the front discs pads and, master cylinder, as this was the consensus from several mechanics. This lasted two days and without warning it happened again, coming to a roundabout, luck was on my side and anybody else as well! Managed to stop called the Mot garage and they came out , by the time they arrived started up tested the van the brakes returned to normal. Have now replaced the vac pump and the servo.
It appears but this is third party from the Ford dealers that they are aware of this problem. It is the servo piston and main spring jamming, in the unit.
My mileage is 118000 so not excessive. Don't anyone ignore this problem its dangerous. hope this helps. Will post this elsewhere.