Mk6 2.4 90hp brake pressure issue and clutch pedal

[JasonK87]

Just bought a mk6 transit 2.4 90bhp

Got a problem with brakes and clutch I'd like a second opinion on

Brakes don't seem to have any pressure, pedal releases slower then usual along with the brakes,

The vacuum pump is leaking bad, previous owner changed gasket but still leaks, a patch the size of a tennis ball under the van when it's stopped running for half hour or so

My question is, would this be effecting the brakes? If the pump is shot. I plan to put a new water pump, vac pump and gaskets so it's all new. Just hope it makes the brakes feel as they should. It's haf new discs and pads but no history of rear cylinders or shoes. Although there's no leaking from rear drums

That's my first problem, next one is clutch, it's very noisey in 2nd 3rd and 5th gear coming down the revs but drives fine with smooth gears, problem is when your foot stays on the clutch in traffic, the clutch disappears and you have to pump the pedal to get it back, I'm guessing this is master cylinder or slave? And the noise is likely to be clutch plate and possibly flywheel

What do you think?

Many thanks
Jason

[loot]

The clutch slave is external on these and is easy to replace if you feel that it needs doing, and the fluid probably wants replacing/bleeding fresh.

If the vacuum pump wasn't working then your brakes would probably be stiff, but it's a good call to replace the vacuum pump with doing the water pump since it is leaking.

If it was me I'd replace the slave and bleed some fresh fluid through and bleed the brakes too, see if that solves it. Cheapest option before replacing the master.
I've just replaced my clutch master, 80 quid

When you say the clutch is noisy does it go if you press the clutch? If so that is more than likely your thrust bearing.
Some ppl leave it til they change the clutch, it's a gearbox out job anyway.

Maybe top the gear oil up as a matter of course.

[JasonK87]

Thanks for reply

I've ordered waterpump, vac pump and clutch master cylinder

Was cheap from transit parts centre, I'm going to order slave cylinder today as well and fit them both before bleeding it. I drove it all day yesterday and never had a problem but previous owner says the clutch disappears in traffic and needs pumping, so master, slave and fluid change/bleed will sort that if it is a issue I'm sure?

The main noise is when you let off the throttle while driving, deceleration in 2nd 3rd and 5th. also slightly noisey when driving/building up speed, soon as you change to 4th it's dead quiet and normal

Putting the clutch down the revs drop and noise obviously disappears

I can't say theres much noise difference on idle when clutch is pressed and released. Only noisey when driving.

Gears and fine though and clutch feels ok other than biting high

is there a chance its gearbox or does that sound clutch/release bearing related?

Think your right, a good fluid change will do it some good I'm sure

[loot]

High bite usually means the clutch is going noise could be dmf or something else.
Thrust bearing is usually if you're in neutral and you press the clutch on and off gently a little you can hear a difference in noise.

[flyingclutchman]

Can't offer any advice on the brakes but can with the clutch! Apart from failing release bearings clutches don't make noises in normal driving. The noise you describe is almost certainly a gearbox noise. First thing to do is check there's oil in the box. It sounds obvious but sometimes a slight leak can lose all the oil over a period of time. It's probably layshaft bearings though as it's quiet in 4th. Someone will correct me if I'm wrong but I believe the gearbox drives directly in 4th rather than 5th. I'm more familiar with the FWD gearbox workings which are totally different, but I think that's how the rwd is set up. Someone much more knowledgable than me will correct me if I'm wrong

[knobby1]

Can't offer any advice on the brakes but can with the clutch! Apart from failing release bearings clutches don't make noises in normal driving. The noise you describe is almost certainly a gearbox noise. First thing to do is check there's oil in the box. It sounds obvious but sometimes a slight leak can lose all the oil over a period of time. It's probably layshaft bearings though as it's quiet in 4th. Someone will correct me if I'm wrong but I believe the gearbox drives directly in 4th rather than 5th. I'm more familiar with the FWD gearbox workings which are totally different, but I think that's how the rwd is set up. Someone much more knowledgable than me will correct me if I'm wrong

Yep...totally agree, I guess 4th is 1:1 ratio straight through the box....5th is overdrive. More than likely layshaft bearings on their way out....

Lord Knobrot

[JasonK87]

I thought this at the back of my mind, guess there's no gaurentee when it will fail completely?

Using it everyday now and the brakes start off soft/spongy then longer I drive (10+miles) the pedal goes really stiff and the brakes stick even more. Does this point to fluid?

Just got to decide if it's worth going further with it and keep it or not, it's a bit of a heap and got nothing going for it other than it's cheap and serves a purpose, mileage stopped on 100k 4 years ago, guessing it's well over 200

This weekend I'll fit slave and master cylinder then bleed everything, see how it is then. If no different then it's going to end up rear shoes and cylinders I guess. Then after all that the gearbox and/or clutch could fail

[loot]

Check the flexi pipes aren't locking

[JasonK87]

Just looked into that and done some research, looks very common

Sounds like my brake problem, Will check flexi pipes tomorrow

Thanks for everyone's help

[JasonK87]

Thanks Loot

Looked at brake hoses this morning and the brackets on the struts were rusty and crushing both hoses, levered out with a screw driver and now the brakes are amazing, pedal feels like a brand new van with no binding so drives really nice

Going to change gearbox oil Sunday, hopefully I'm lucky there too

Well happy, thanks again

[loot]

Sweet i had it on a mk6 escort, you'd think that Ford would sort it out Lol
Mind you, i don't suppose rust is common knowledge?

[JasonK87]

Would of never of thought of hoses being crushed by rust

Good old ford