hmmmmm well ongoing and various braking issues!

having not been happy with the brakes for sometime ive had the handbrake cables replaced- handbrake still pants!
new shoes, drums, disks and pads

brakes work but on the second or third time foot goes to pedal pedal is hard and car stops a lot slower. Garage had a look- first it was one pipe, then it was another pipe. Long story short still has this issue after £200 on pipe replacements so they have diagnosed a new servo is needed.

So three questions- is it likely to be that? as its an expensive do if it doesn't work!

how much is the part? and how much would you expect the garage to charge?

oh ok four questions! handbrake light came on for around five mins today whilst driving (handbrake not on!) then went off again is this likely to be connected?

I really like this car but not being mechanically minded has led to thousands being paid out on 'minor' issues.

Oh im in North Wales if anyone can recommend a good mechanic/garage?

The vacuum system for the brakes on a TD4 is connected to many and various systems around the engine bay by a network of small diameter rubber pipes that are prone to cracking and rubbing on other components.

From the vacuum pump, a line goes to the servo, there are various T-connections, with a line going to the EGR solenoid and then the EGR valve, another line going behind the engine to the turbo VNT solenoid and on to the turbo itself. There is also the "inlet" to the vacuum system over there which is another line from the VNT solenoid with a small filter on the end - other end of the filter is just open to the air.
There is also a vacuum reservoir - an oval plastic webbed bulb a bit bigger that a fist, which is located on the line to the VNT.

All these pipes need to be carefully checked and possibly replaced - its just small bore braided rubber hose which any motor factor should sell cheaply by the meter. The hose tends to crack around the ends where the connections are, and the line to the VNT can rub on the gear linkage. Any small leaks mean you will loose vacuum pressure.


If after all that you still need a new servo - well, its not that big a job. I would be surprised if it took a garage more than an hour or so.



As for the handbrake - poor handbrake is common, but easily fixed. If you have new cables, shoes and drums, then it should be perfect. That auto adjustment mechanism on the rear shoes needs to be completely free to move. On mine the toothed wheel was quite worn so was not being turned by the lever arm. A few minutes with a small triangular file soon fixed them and now the handbrake works fine.


The handbrake light coming on while driving could relate to low brake fluid level - check the level at the master cylinder.

thanks for your reply- where do I check brake fluid levels? (im REALLY not mechanically minded)

also having had many costly pipe replacements they think it is now the servo, how much is the part for 2002 td4? all I know is garage want £375 for parts and labour and I have already spent £200 chasing this problem : (

would the handbrake adjuster not be checked when the new cables went on? again having spent a lot of money chasing handbrake problems im reluctant to take it back to the garage AGAIN about the handbrake. In a cycle of giving them my car and then being charged a few hundred pounds and the problem not being solved and its getting boring now!!!

The fluid level is checked in the plastic reservoir directly above the servo. It has a screw cap and the side of the reservoir will be stamped with min and max marks.


I would suggest you need to find a better garage.

thanks Dave much appreciated!

I keep hoping someone on this forum can point me in the direction of a good garage