300TDI Vacuum Pump stuffed

[jboot51]

Pump had a small oil leak, more of a weep, has been there for a long time.
Finally got around to removing it with the intention of doing the nut and bolt mod to replace the rivets.
I must say it is not the easiest thing to remove.
Managed to pull it apart, this is what I found.
The piston seal is just about gone.
Pitting on the piston.
No debris in there.
Damage is all at the lowest point
Surely wasn't going too last much longer.

[rick130]

Consensus seems to be to get a Bearmach replacement, don't touch an OE Wabco with a barge pole.

Mine hasn't been in long enough to confirm this, but that's the way I jumped.

[jboot51]

Just finished installing the new one.
It's a Wabco in a Bearmach box.
The cover is still riveted, I thought they changed them to torx bolts.

Seems my brakes are a little better, less effort for braking force,
might have been low on vacuum.

As there is only one seal, it would make sense that the vacuum would be leaking when running and oil would leak when stopped.

[rick130]

Just finished installing the new one.
It's a Wabco in a Bearmach box.
The cover is still riveted, I thought they changed them to torx bolts.

Seems my brakes are a little better, less effort for braking force,
might have been low on vacuum.

As there is only one seal, it would make sense that the vacuum would be leaking when running and oil would leak when stopped.

Really ?

The one I bought was painted black not anodised, no identification in a Bearmach box ?

[bretty15]

ive got 6 dead ones in the shed the last one only lasted 2000km when it seezed up and the one on there now leaks oil was looking at going back to alternater vacume pump

[460cixy]

Wouldn't think there would be enough room to run an alt with a vac pump look on eBay for a 12 volt vac pump would do the trick

[wrinklearthur]

What do you think about this one?

12 volt electric vacuum pump brake booster vacuum pump 12 volt new | eBay (http://www.ebay.com.au/itm/12-volt-electric-vacuum-pump-brake-booster-vacuum-pump-12-volt-new-/230879547411#ht_500wt_1203)

.

[460cixy]

That would be fine. I forgot to mention there expensive but so is the original I guess

[steane]

You should really replace the brake booster when you replace the vacuum pump.

I bought a new Wabco and couldn't get warranty unless I bought a new brake booster and did both. The boosters split and leak (hairline cracks around the mounts I think), it's a known fault, and the leak forces the vacuum pump to work overtime and kill itself.

Chatting with All 4x4 spares, they told me they had all sorts of issues with the vacuum pumps until someone worked out it was actually the brake boosters that are the issue. Is Defender specific and you are best to assume that your brake booster has the cracks, because its very common.

I've had no issues with the Wabco. Done about 5,000kms now. Replacing both pump and booster made a big difference to the brake feel.

[Bushie]

If you do replace the booster, go for a genuine or at least a known brand.

I replace mine a while back with an after market and couldn't get a good pedal feel - I wonder why ?

https://www.youtube.com/watch?v=wU3CyjTFiZ4

Martyn

[460cixy]

Wow I have seen boosters and firewalls move and flex before but nothing like that pile of crap

[rick130]

Wow I have seen boosters and firewalls move and flex before but nothing like that pile of crap


It's a goodun, isn't it.

I remember when Martyn first posted that vid up and I was gobsmacked.

[460cixy]

What brand was it ?

[Catman]

Hi all, there's a lot of interesting reading relating to leaking vacuum pumps on the 300tdi. The question I have is: has anyone used the non-genuine Chinese sourced pumps (I think anything without a Wabco tag would be Chinese sourced) & if so, what is the success rate? Thanks, Rob.

[87County]

we bought a non-ome one from karcraft (made in india?) and fitted it about 20000 km ago - so far, so good

at karcraft's recommendation we used 2 gaskets to position it out marginally from the camshaft

I wonder if this simple addition would have overcome some of the wabco failures.

[wrinklearthur]

we bought a non-ome one from karcraft (made in india?) and fitted it about 20000 km ago - so far, so good

at karcraft's recommendation we used 2 gaskets to position it out marginally from the camshaft

I wonder if this simple addition would have overcome some of the wabco failures.

I didn't hear that from Karcraft, but I have found that using two gaskets is the way to go.
.

[rick130]

An update.

Popped the bonnet on Friday and said to SWMBO, "we're taking your car to town"

One of the welsch plugs has gone ta ta from the vac pump, oil everywhere.
Luckily the engine is only down 1l or so.
Lobbing into a mates this morning to turn a plug up from some aluminium stock to get going again.

:rolleyes:

[rick130]

Found a 22mm welsch plug, applied Stag and carefully tapped it in, (the casting is aluminium and thin) we'll see how it goes.

[Judo]

An update.

Popped the bonnet on Friday and said to SWMBO, "we're taking your car to town"

One of the welsch plugs has gone ta ta from the vac pump, oil everywhere.
Luckily the engine is only down 1l or so.
Lobbing into a mates this morning to turn a plug up from some aluminium stock to get going again.

:rolleyes:
Bugger. And here I was about to order a Bearmach replacement based on your previous post!! Did you use 2 gaskets Rick?

[rick130]

No,didn't know about the two gasket trick at the time and it was all supplied by Karcraft, but the new gasket was pretty thick.

[Jode]

Found a 22mm welsch plug, applied Stag and carefully tapped it in, (the casting is aluminium and thin) we'll see how it goes.
Sorry Rick, but what's Stag when it's at home? Haven't come across that in this neck of the woods....

Jode

[wrinklearthur]

Sorry Rick, but what's Stag when it's at home? Haven't come across that in this neck of the woods....
Hi Jode

It's a jointing paste for plumbing, etc...

https://www.aulro.com/afvb/images/imported/2013/06/75.jpg

.

[rick130]

Hi Jode

It's a jointing paste for plumbing, etc...

https://www.aulro.com/afvb/images/imported/2013/06/75.jpg

.

And been used since Adam served his motor mechanics apprenticeship in the Oz Garden of Paradise Garage as a sealant for welsch plugs in engine blocks, etc too.

[philco]

does any one know what size bolt and nut to replace the rivets on the vacuum pump?
I didn't want to drill one out then find i got to drive out to get the right size bolt as my guesstimate was wrong.

[Judo]

^ I'm thinking of trying this as well, but have bought another unit just in case I screw it up.

Also, am I assuming correctly that when the pump is leaking oil, there is in theory nothing wrong with the pump, except the plastic case is coming apart at the seam? Thus the rivet->bolt trick being a good solution? Or is there more to it than this?

Just want to ensure I'm not implementing a bandaid fix... :)

[philco]

I found this very helpful article for repairing vacuum pump, not sure if anyone else has seen it.
The bolts to use are 3/16 x20-25mm long, they suggest using washers also.

vacuumpumpfix (http://www.the4wdzone.com/vacuumpumpfix.htm)