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2004 2.5 tdi VW lt 28 brake issues

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mojo View Drop Down
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Joined: 04 Dec 11
Location: Liverpool
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mojo Quote  Post ReplyReply Direct Link To This Post Posted: 24 Nov 19 at 20:48
I have a feeling the previous owner may have removed a bulb or two from the dash. How long have you had the van?
There should be four abs sensors and the pain in the arse bit is they are a nightmare to remove (when they're fitted) and they are hard wired into the ecu, when replacing them the original wiring has to be cut and then join the new wiring/sensor. I fitted a weatherproof connector plug on my new sensor rather than hardwire it up again just for future convenience if the knuckle ever has to come off. I couldn't remember which warning light came on when the sensor was removed so I've just unplugged the abs sensor and checked, it's the immobiliser light (the yellow light on the right with the circular arrow) which comes on and stays on solid.
2006 LT35 TDI 109 AVR
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Cornwall87 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Cornwall87 Quote  Post ReplyReply Direct Link To This Post Posted: 07 Dec 19 at 15:12
Brilliant thank you, I'll take the dash apart soon.

I've now replaced the master cylinder, the disks, pads and all calipers, the load compensating valve. Still the same.

With the vacuum entirely disconnected the brakes are about the same as with it on. I've bled and bled the system now. Its had around 3l of fluid.

I have vcds on the way but its coming from Australia so it may take a while.

The pedal falls away under pressure and it's not safe to be out on the road currently, it's like the brakes have no force at all, I'm running out of patience now Haha.
Thanks for your continuing help here 
Simon 
SWB VW LT 28 2.5TDI
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mojo View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote mojo Quote  Post ReplyReply Direct Link To This Post Posted: 07 Dec 19 at 20:20
The only thing left is the servo! If that doesn't sort it.... a can of petrol and box of swan vestas should haha.

If you pump the brake pedal with the engine off does it stiffen up, if it does, keep your foot on the pedal and start the engine, you should feel the vacuum assistance help draw the pedal lower.
2006 LT35 TDI 109 AVR
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Cornwall87 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Cornwall87 Quote  Post ReplyReply Direct Link To This Post Posted: 07 Dec 19 at 21:16
Yup pedal goes solid with the engine off, and the pedal creeps down with the engine started. Hopefully when vcds gets here I can properly purge the abs pump. I'm wondering if the new master cylinder could be knackered.
It doesn't feel good trying to stop it, theres just no force there at all.

Thanks for replying, I thought about the can of petrol solution too haha
SWB VW LT 28 2.5TDI
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