 | Home > Maintenance & Modifications > TD5 brake booster rust and Cracks. |
 
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| donmacn Member Since: 06 Nov 2017 Location: Nth Scotland Posts: 1845  
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I didn’t know you guys got rust down there!
My experience is 300Tdi, but in this instance I don’t think that matters much. This is a common enough problem. The servo flexes there, and eventually will crack. To replace it isn’t a big deal, there will be enough flex in the brake lines (usually) to allow the master cylinder to be unbolted and gently moved forward enough to allow the servo to be removed/replaced. Although it’s cracked, it might not be leaking a vacuum just yet though. If you’re replacing the servo, try and get a good brand. I’ve used TRW. As for the rust between the reservoir and cylinder, I wouldn’t have thought that would be a problem, but a picture would help. Donald 1994 Defender 300Tdi 110 SW - owned since 2002 - 230k miles and going strong (The 'rolling restoration' or tinkering thread: http://www.defender2.net/forum/topic58538.html ) 2000 Range Rover P38 4.0L V8 in the past.. RR classic - fitted with 200Tdi 1984 RR classic - V8 with ZF auto box 1993 Discovery 300Tdi not to mention the minis and the Type 2 VW camper... |
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11th Feb 2024 8:03pm |
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| MalteseRover Member Since: 02 Jul 2013 Location: Gozo Posts: 137 
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hello, sorry I got to you so late. i am rebuilding all calipers (shot blasted) and primed at the moment with old pistons still on. will rebuild them with s.steel ones once top coat is hard dry.
Here is the picture of the cracks (there is one on the opposite side too. It all braked perfectly until i felt pedal vibratians (resulting from pads getting worn unevenly and there was metal to metal contact. DO you think it is possible to gently tack it in with a Mig welder on low setting one spot at a time? How can you test if the servo is doing its job well?  Click image to enlarge |
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18th Aug 2024 2:31pm |
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| Oldowner Member Since: 26 Dec 2018 Location: South west Posts: 623  
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You don’t need to test it as it is completely knackered, it also hasn’t “braked perfectly” for some time.
You also don’t weld brake components, you buy a new servo. However you can out of interest spit on the crack when running and watch it magically disappear into the crack. A good servo with engine turned off after a minute or so should still hold a vacuum, proven by removing the one way valve / hose tail from servo when you will hear a whoosh from the incoming air. |
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19th Aug 2024 12:40am |
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| MadTom Member Since: 10 Sep 2013 Location: Olomouc Posts: 623  
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I had the same problem with rusty and broken brake servo on two 130 TD5, just replaced with new one. Steering and brakes are the most critical parts of the car.
I have opened the old servo, sandblasted rust spots, welded and grinded broken holes, and stored it as spare part for temporary use/test part. It was not easy to spot broken hole, because it was hidden behind main brake valve, so sometimes a test spare part is nice to have, to be sure, where is the problem, before going to byu a new one. "Drobek" = The Small One - Discovery 2, "Blufínek" = The Blue Thing - Defender 130, and for me at least Ford Mondeo  |
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19th Aug 2024 5:57am |
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| Mo Murphy Member Since: 01 Jun 2008 Location: Letchworth Garden City, Herts Posts: 2241 
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That's scrap, replace it. All single diaphragm servos on 90s and 110s eventually die like this. Sure you could weld it but the rubber diaphragm inside is likely to long be past it's best.
HTH Mo The Land Rover 90 - Many are called, few are chosen. 50 Shades of Pennine Grey |
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19th Aug 2024 11:59am |
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| BaronDefenders Member Since: 28 Jun 2019 Location: London/Cotswolds Posts: 896 
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I agree with Mo. Bin it and fit a new replacement. It’s a simple job and the only fiddly bit is the R-clip inside the pedal housing. Charlie
1949 Series 1 80 (SOLD) 2002 Td5 90 (SOLD) 2008 Freelander 2 (SOLD) 1958 Series 2 88 Pastel Green (2019 LR Legends Best Restored) 1983 V8 110 Limestone (Previously owned by Tom Sheppard MBE) 2004 Td5 90 Santorini Black (Td5INSIDE Powered & Rebuilt by CSK) 2012 Puma 110 Zermatt Silver (Overlanding Build) Instagram: @BaronDefenders |
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20th Aug 2024 6:43am |
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