Discussion
Hi all
Dragged the wedge from a very long winter slumber last weekend
A few bits needed fettling after being laid up for so long (8 months or so
) but got back on the road yesterday
Decided to take the wife out for a cool drink this afternoon and on Our way to the pub hit the brakes to slow for a car turning right
All was good for a few moments then I felt something “give” in the brakes - pedal goes really hard and brakes are failing to stop the car
Press pedal really hard, car stops, change underwear, apologise to very angry wife
Symptoms are that brakes work straight and true but need a lot of force on the pedal to make them bite and the pedal only returns up to the top of the travel very slowly like it’s wading through treacle
My diagnosis is a failed servo
A bit of searching reveals that the wedge servo (350) is ex cortina/ Capri
8” dia with take off at 12 o’clock
So been looking for a replacement without luck
There’s a couple on the bay but both look wrong - take off in wrong position
Anyone have a source for a replacement please or possibly has anyone found something else that fits ???
All hoses unions checked btw so not a leak
Thanks all
Ron
Dragged the wedge from a very long winter slumber last weekend
A few bits needed fettling after being laid up for so long (8 months or so
) but got back on the road yesterday Decided to take the wife out for a cool drink this afternoon and on Our way to the pub hit the brakes to slow for a car turning right
All was good for a few moments then I felt something “give” in the brakes - pedal goes really hard and brakes are failing to stop the car
Press pedal really hard, car stops, change underwear, apologise to very angry wife Symptoms are that brakes work straight and true but need a lot of force on the pedal to make them bite and the pedal only returns up to the top of the travel very slowly like it’s wading through treacle
My diagnosis is a failed servo
A bit of searching reveals that the wedge servo (350) is ex cortina/ Capri
8” dia with take off at 12 o’clock
So been looking for a replacement without luck
There’s a couple on the bay but both look wrong - take off in wrong position
Anyone have a source for a replacement please or possibly has anyone found something else that fits ???
All hoses unions checked btw so not a leak
Thanks all
Ron
gmw9666 said:
Capri 1.6 / 2.0.....not the 2.8 though
However it’s not a straight swap as the TVR has an adjustable Clevis and the ford unit is fixed.
Net net you will need to modify the rod or make / use a 20-25mm spacer (search TR6 for spacer)
OR
Buy a new one for big £££ off tvr parts
Oh joyHowever it’s not a straight swap as the TVR has an adjustable Clevis and the ford unit is fixed.
Net net you will need to modify the rod or make / use a 20-25mm spacer (search TR6 for spacer)
OR
Buy a new one for big £££ off tvr parts
Found a new one on line £300 plus vat and delivery
also out of stock at the moment RobXjcoupe said:
If you get the unit out and apart and need something made up to make it work let me know via an email and I’m sure I can make that part for you. I won’t charge you mega bucks either just like making bits 
Thanks fellaWill bear that in mind but my biggest challenge is going to be finding one at the moment... unobtanium is the word springing to mind
mrzigazaga said:
You could give Clive a call at Tickover in Dartford...he might have one laying about...not sure if he can service the old one...
Old ones fubar - really crusty on the underside Have ordered a ka one off the flea will have to do a comparison against the old one to see if it’ll be compatible
The Tvr s forum have had similar discussions and a ka one is mentioned as a possible replacement.... we’ll see- I’ll keep you posted
Morning all
In response to your replies
From earlier forum posts common consensus is that the master cylinder and servo for all wedges are from small engined varieties of Capri (mk 2/3) or cortina(mk 3/4/5). This was carried over onto production of the first batch of the S when it was reintroduced after the wedge production stopped (89-90 ?)
The S then used a Saab set up
Over on the S forum there’s been a discussion or two on servos etc as they’re in the same boat as me - no readily available replacement it’s been said also that a Ka one is suitable for the S hence my ordering one in the hope it’ll do for the wedge. It’ll probably need some/ lots of modification but I’ll see when it arrives - it might not fit at all !!
Not sure where you got TR6 from glen ???
I’ve got vacuum so defo servo u/s
Take off is what I mean by where the vacuum hose attaches Wilf- looking from the front the master cylinder bolts are at the 3 and 9 o’clock positions on the servo and hose connection is at 12 o’clock- same as small engines capris and cortinas- on bigger engined stuff the servo is slightly larger and hose connection is at the 2 o’clock position
Photo to follow
Thanks Ron
In response to your replies
From earlier forum posts common consensus is that the master cylinder and servo for all wedges are from small engined varieties of Capri (mk 2/3) or cortina(mk 3/4/5). This was carried over onto production of the first batch of the S when it was reintroduced after the wedge production stopped (89-90 ?)
The S then used a Saab set up
Over on the S forum there’s been a discussion or two on servos etc as they’re in the same boat as me - no readily available replacement it’s been said also that a Ka one is suitable for the S hence my ordering one in the hope it’ll do for the wedge. It’ll probably need some/ lots of modification but I’ll see when it arrives - it might not fit at all !!
Not sure where you got TR6 from glen ???
I’ve got vacuum so defo servo u/s
Take off is what I mean by where the vacuum hose attaches Wilf- looking from the front the master cylinder bolts are at the 3 and 9 o’clock positions on the servo and hose connection is at 12 o’clock- same as small engines capris and cortinas- on bigger engined stuff the servo is slightly larger and hose connection is at the 2 o’clock position
Photo to follow
Thanks Ron
|https://thumbsnap.com/0MYyicIH[/url]Engineer1949 said:
found this
//www.ebay.co.uk/itm/Ford-Cortina-MK4-5-All-Models-1979-1981-Girling-74049208-Brake-Servo/123095626537?epid=25018426116&hash=item1ca9123329:g:VLwAAOSwb~Ja3ebW
john
Saw that but the picture isn’t right //www.ebay.co.uk/itm/Ford-Cortina-MK4-5-All-Models-1979-1981-Girling-74049208-Brake-Servo/123095626537?epid=25018426116&hash=item1ca9123329:g:VLwAAOSwb~Ja3ebW
john
Think that’s the larger servo with the vacuum connector at the 2 o’clock position
Mine is the smaller one with vacuum connector at 12 o’clock
gmw9666 said:
Looks kind of correct but without dimensions it’s hard to tell if it’ll fit 
It’s clear to see why my servo went pop 😀
Obviously rotted out before and someone’s slapped loads of plastic padding over it as a “repair”
The Ka servo arrived and as Glenn predicted it’s a no go
There’s lots of differences between it and the original the main thing is that it’s just too big
Original is 190 mm dia
Ka is around 240 mm dia
I’ve got a very good car spares shop local - might try to get down there and see if he can use the catalogues he keeps to find something
Ron
Hi all
Thanks Glen - missed the eBay one though
As Sabre said wouldn’t have thought tr6 as it went out of production about 6 years before the start of wedge production TR7 would be more likely??? Found this old thread https://www.pistonheads.com/gassing/topic.asp?h=0&...
Steve Heaths comments (5th post down) are interesting but a little worrying as well !!!
It’s s bit annoying that there doesn’t seem to be any identifying marks on the servo to help identify it at all - all I know is that hat it’s Girling
Thanks Glen - missed the eBay one though
As Sabre said wouldn’t have thought tr6 as it went out of production about 6 years before the start of wedge production TR7 would be more likely??? Found this old thread https://www.pistonheads.com/gassing/topic.asp?h=0&...
Steve Heaths comments (5th post down) are interesting but a little worrying as well !!!
It’s s bit annoying that there doesn’t seem to be any identifying marks on the servo to help identify it at all - all I know is that hat it’s Girling
Edited by Rockettvr on Thursday 10th May 21:02
Morning all
My servo issues are solved - thanks to Glen
Ordered one of these https://www.moss-europe.co.uk/brake-servo-assembly...
Wasn’t sure it’d fit but found a thread about fitting a ford master cylinder to a tr6 servo
https://www.pistonheads.com/gassing/topic.asp?h=0&...
So thought it might be ok
Happy to report that it fits fine - the only issue being as Glen said is the Clevis needs adapting - I cut the old one off and welded it to the new servo
Also on the new one the “drum” part of the servo is dimensionally smaller 90mm deep and 170mm ish dia as opposed to 100mm and 190 mm ish
But mounting bolts etc are exactly the same
Wether the smaller dimensions make much difference time will tell
Fitted last night and all seemed good will report back once I’ve given it a road test
Ron
My servo issues are solved - thanks to Glen
Ordered one of these https://www.moss-europe.co.uk/brake-servo-assembly...
Wasn’t sure it’d fit but found a thread about fitting a ford master cylinder to a tr6 servo
https://www.pistonheads.com/gassing/topic.asp?h=0&...
So thought it might be ok
Happy to report that it fits fine - the only issue being as Glen said is the Clevis needs adapting - I cut the old one off and welded it to the new servo
Also on the new one the “drum” part of the servo is dimensionally smaller 90mm deep and 170mm ish dia as opposed to 100mm and 190 mm ish
But mounting bolts etc are exactly the same
Wether the smaller dimensions make much difference time will tell
Fitted last night and all seemed good will report back once I’ve given it a road test
Ron
Unexpected side effect :
Since sorting the servo my wedge has run badly from cold hunting really bad at idle and a little once warm. Cuts out occasionally on coming to a stop at lights etc
Thought it may be a problem with the new servo so disconnected the vacuum pipe and car runs well with no hunting but a high idle speed 2k rpm ish.
Conclusion:- old servo was letting a little air into the intake system allowing the car to run at a higher rpm at idle - previous owners remedy was to screw the idle screw on the plenum virtually all the way down to reduce idle speed
Cure: reconnect servo, screw idle screw all the way in and then unscrew 2 turns - idle restored
Who would have thought that replacing the servo would screw with the idle speed ? !!
Since sorting the servo my wedge has run badly from cold hunting really bad at idle and a little once warm. Cuts out occasionally on coming to a stop at lights etc
Thought it may be a problem with the new servo so disconnected the vacuum pipe and car runs well with no hunting but a high idle speed 2k rpm ish.
Conclusion:- old servo was letting a little air into the intake system allowing the car to run at a higher rpm at idle - previous owners remedy was to screw the idle screw on the plenum virtually all the way down to reduce idle speed
Cure: reconnect servo, screw idle screw all the way in and then unscrew 2 turns - idle restored
Who would have thought that replacing the servo would screw with the idle speed ? !!
Hi Adam
In bought the one in Glens post - well I googled the part number GSM90156Z and found one on eBay for £103 from David manners group (jag parts people)
My first thought was also to run a thread onto the shaft 8mm as existing but the shaft is a little too big for an 8mm die but a bit too small for anything else
Also the shaft will rotate and has some lateral movement and I couldn’t see an easy way of holding it steady to doo inch with it so I took the path of least resistance and cut the shafts and welded on the old one
Ron
In bought the one in Glens post - well I googled the part number GSM90156Z and found one on eBay for £103 from David manners group (jag parts people)
My first thought was also to run a thread onto the shaft 8mm as existing but the shaft is a little too big for an 8mm die but a bit too small for anything else
Also the shaft will rotate and has some lateral movement and I couldn’t see an easy way of holding it steady to doo inch with it so I took the path of least resistance and cut the shafts and welded on the old one
Ron
Hi Jon
Good to see you’re still in the wedge club
Wot I did:
disconnect vacuum hose
Undo 2 nuts holding on master cylinder and gently pull it off the studs
Undo 4 nuts in footwell and the shaft to pedal coupling
Pull servo out
It may be that yours is the same as mine and has had a good dollop of sealant applied to the joint between the servo and bulkhead to waterproof it
Hope that helps
Ron
Good to see you’re still in the wedge club
Wot I did:
disconnect vacuum hose
Undo 2 nuts holding on master cylinder and gently pull it off the studs
Undo 4 nuts in footwell and the shaft to pedal coupling
Pull servo out
It may be that yours is the same as mine and has had a good dollop of sealant applied to the joint between the servo and bulkhead to waterproof it
Hope that helps
Ron
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