cutting out when braking

[type53b]

Hi all, long story short, driving to work yesterday morning when a total fu%kwit pulled out of the hard shoulder right in front of me to go to the petrol station across the road. I slammed on the brakes but still hit her and spun her around. I got out to talk to her but she was acting really odd. And I mean really odd! She continued on into the garage, filled her car with petrol,paid for it and then promptly legged it. That's just the short version. Lots more happened between the initial crash and her driving off. Anyway ,after the first few sentences between us, I decided that she had probably tooted a lot of Columbian marching powder, so I rang the police. And they arrived about 15 minutes after she had buggered off. Typical. Anyhoo, showed them pictures of her , her car ,her reg number and the said they would investigate and contact me. So I continued on into work and that was that. But now ever since, the brake pedal feels rock hard and the car keeps cutting out when coming to a stop. Its not leaking any brake fluid and it stops fine but cuts out all the time. I have a feeling something has gone kaput in the master cylinder because I stomped on the brake pedal so hard. It had all new discs ,pads , stainless steel braided hoses, new rear shoes and cylinders and fluid flushed out. New fluid and bled out about 1000 miles ago. The master cylinder was the only thing that was not changed. Any idea's???

[james butler]

could be master cylinder issues but it sounds more like servo issue ( the big black drum master cylinders bolted too)
check the vac pipe between manifold and servo is hooked up OK and not split and also check the yellow one way valve is working properly.
one way to test the servo is to pump the brake pedal with engine off until it goes rock hard.
then with the pedal pressed down turn the engine over and you should feel it sink half an inch.
if it doesn't the servo has had it.

[type53b]

Cheers James I will check this and report back. Many thanks!

[type53b]

Can the servo be reconditioned or serviced ? Or is it just better to replace it ?

[type53b]

Right I tested the servo the way James said and it is not working. So it looks like I will have to replace it. Is there a how to anywhere on the forum for this? Many thanks.

[james butler]

here is an upgrade how to instruction
https://vwgolfmk1.org.uk/index.php?page ... misc&id=28
use the info on removing the old stuff to give you an idea.
first you need to remove all the brake pipes from the master cylinder
second unbolt and remove the master cylinder
third undo the four bolts holding the sevro on
fourth remove pins from the clevis at the back of the servo so it can be detached from the pedal assembly linkage.
be warned theres a mahoosive spring in there somewhere thats a bit of a pain to get back in place so be patient with it when putting it back together.
its up to yu but i would do the 22mm master cylinder and servo upgrade while your there

[james butler]

Can the servo be reconditioned or serviced ? Or is it just better to replace it ?

replace/upgrade is the only safe way

[type53b]

Thanks for the good advice James,its very much appreciated! I have sourced a good secondhand servo and will be picking that up on Wednesday. Hopefully everything goes well.I will let you know how I get on.once again,thanks.

[unknownmale]

Can the servo be reconditioned or serviced ? Or is it just better to replace it ?

replace/upgrade is the only safe way

Do you know the diameter of part number of the 16v booster? Been thinking of doing this upgrade for a while.

[unknownmale]

Nevermind, found it - 358612105

[james butler]

i know ants old 20v turbo he fitted the brake booster and master cylinder from the audi a3 and said he had great results
i used a 16v abf mk3 golf servo by cutting off the ball on the back and threading it myself to fit the clevis.

[unknownmale]

Can you use the original master and the 16v booster or is the bolt pattern different?

[james butler]

the master cylinder is annoyingly longer on the 16v where it goes into the servo so the shorter 8v cylinder doesn't work with it.

[james butler]

are you coming to the nationals?

[james butler]

if you are i have a bright red servo with your name on it!
i don't know if it works as I've never tested it but they don't really fail that often it must be said.