Brake Servo Failed

[ProjectChimaera]

Think this one might have had it! Mighty glad it deposited huge quantities of brake fluid in the footwell before I got new carpets etc.
Removing the master cyl, servo and pedal box isn't much fun. For future info, releasing the pipes from the connection block on the bulk head, undoing the master cylinder bolts and releasing the pedal box allows the master cylinder and pipes out through the top with the reservoir removed.Detatched throttle pedal and pivot spindle from pedal box, also bonnet cable. Split servo from pedal box and the pedal box will come out without removing steering column. It's much easier to undo the pipe connections to master cylinder in the vice as mine were brass and very tight.
I knew there was a lot of fluid in the servo by dipsticking the servo through the vacuum hole. Scarily I poked around the servo rusty bits a little and the two halves separated.

[ProjectChimaera]

ClassicChimaera said:

What year is your car.

1998 vintage!
It's pretty amazing that with all new brake pipes and calipers etc. that it all bled up well with a good pedal and servo operation!
Only after it was left standing did it leak back and out!

[ProjectChimaera]

RobXjcoupe said:

N7GTX said:

RobXjcoupe said:

N7GTX said:

RobXjcoupe said:

The brake master cylinder failed on my Griff about 3 years ago, servo wasn't too bad, with a bit of surface rust. The master cylinder was of fiesta 1.8 diesel spec though. Was wondering if the slightly later fiesta mk4/5 have the same servo as the mk3 fiesta. Same basic car?

Looked this up. The Mk3 Fiesta had an 8" servo and the Mk4 has a 9" servo. So unless someone has actually fitted one it doesn't look good.

I imagine in true Ford fashion the mk4 fiesta version bolts up the same as the earlier version. It's the clearance needed within the TVR.? I have no idea if it's a close fit or has room around it to accommodate the slightly bigger servo? £30 buys a second hand fiesta mk4 brake servo, just need someone with their TVR apart to try it?

When you look down into the void under the clutch master cover, the clearance on the outside is very tight at the bottom.
You can get an idea of the condition of the brake servo by opening the driver's door, getting down on your knees and with a torch look towards and behind the accelerator pedal. About a third of the servo is clearly visible behind the accelerator pedal on the outside and if yours was as bad as those in this thread you would probably see it here. You can also check for any leaks from both the brake and clutch master cylinders while you're at it.
Then get someone to help you get up off your knees.....

That picture is my servo and pedal box from 3 years ago. My servo had a bit of surface rust but nothing to worry about. The master cylinder failed hence the strip down

I looked at the later Fiesta servo and master cylinders and it's quite different. The orientation of the ms to servo mounting is different. I'm pretty sure that another combination could fit with some mods but it may result in the master cylinder reservoir being in a different position and then a sealed cover would be needed for the inner wing.
A quick check of the servo is to pull out the vacuum pipe and to dipstick the inside of the servo to check for any internal brake fluid. If you are planning to remove your servo then I would advise sucking excess fluid out through this hole first, I didn't and it deposited about a pint of brake fluid in the footwell as I was removing it, not pleasant!

[ProjectChimaera]

New master cylinder located by a local supplier. Manufactured in Italy according to the packaging.
Cast type not steel.
These are available for about £60 + PP and VAT. Please message me if interested and I'll put you in contact with the supplier.

[ProjectChimaera]

Pedal box and bits all painted up and ready to refit, can't say I'm looking forward to being upside down much!
Thanks to Sardonicus for help with the new servo, much appreciated.
Hopefully won't ever need to do this awkward job again.