AU1 danger warning plastic brake boosters!! - Page 2

GK · 18-05-2006, 09:13 PM

Quote:

Originally Posted by I6corp

Calm down guys, honestly i didnt take EFFalcons question, as a bad thing!

Neither did I.

GK

GK · 18-05-2006, 09:14 PM

Quote:

Originally Posted by buickman

Being 2 boosters now that has given you problems I would be looking at the master cylinder or a leak somewere as well as the calipers that might be blocked with dirt that might be some cause of the problem.

Agreed!

GK

**Stav** · 18-05-2006, 10:31 PM

Quote:

Originally Posted by FordGirl

You overlook all the cabbies in this country? If there was an actual problem with them, you would've thought people would say "hey, that happened to me too!". I dare say its a problem with your car...

It looks that way. It seems to be the cars fault somewhere. However considering the wrecking yard I dealt with have 90% of their business from cabbies I believe them when they say theyve sold heaps of those units but not one au2 booster.

I bled the brakes like dracula last night and the pedal feels significantly higher.So hopefully this will fix the issue.

I dont beleive the master cylinder should end up with a ripped diaphram..should it?

**Stav** · 18-05-2006, 11:23 PM

http://www.aa1car.com/library/pwrsteer.htm

The amount of power assist that's actually provided by the booster depends on two things: the size of the diaphragm and the amount of intake manifold vacuum produced by the engine. The larger the diaphragm, the greater the boost. An 8-inch booster with 20 inches of engine vacuum will provide about 240 lbs. of brake assist

Ok well I know what will fix it and make it safer then.The au2 booster. I am not taking chances with dilly dally.If ford wanted to cut corners and I lose my brakes 2 times already well bugger them.I am not taking the risk.I am going to modify my firewall and stick this in.THE AU2 BOOSTER.

I6corp · 19-05-2006, 01:02 AM

Quote:

Originally Posted by GK

Neither did I.

GK

Good,

and i think that is ur best option Useless, tell us how it goes.... and maybe a walk through article, for all us future AU1 owner's.

Cheers

Racecraft · 19-05-2006, 03:12 AM

Quote:

Originally Posted by useless

Ok well I know what will fix it and make it safer then.The au2 booster. I am not taking chances with dilly dally.If ford wanted to cut corners and I lose my brakes 2 times already well bugger them.I am not taking the risk.I am going to modify my firewall and stick this in.THE AU2 BOOSTER.

I dont know how that will go mate.. They are a different unit for the twin piston callipers.. IIRC the EA was one steel, I'd try and find one that was set-up for the single piston brakes....

**Stav** · 19-05-2006, 08:32 AM

Quote:

Originally Posted by Racecraft

I dont know how that will go mate.. They are a different unit for the twin piston callipers.. IIRC the EA was one steel, I'd try and find one that was set-up for the single piston brakes....

I was told that the master cylinder is exactly the same unit.

XR6-VCT-2000 · 19-05-2006, 08:52 AM

Quote:

Originally Posted by useless

I was told that the master cylinder is exactly the same unit.

It pretty much is ;) , its just bigger . I cant see it being a problem using it for a single piston caliper setup - i just wouldn't recomend go using a booster for a single piston caliper setup if you had a double piston caliper setup on your brakes.

eXi7w0unD · 19-05-2006, 09:31 AM

i got an au 1, nothing wrong wit my brakes. cept i need new rotors and pads !

**Stav** · 19-05-2006, 07:56 PM

I found a rip!! What I also found is that the rubber edging has gone hard / brittle causing cracking.But looking at the booster form inside the engine bay the damage is at say 4 oclock.Between 4 and 5 oclock their is a brown residue left. I can only guess that it could be degreaser having gotten in.It is also adjacent the extractorsbut I dont think it is the heat. I have now come to the conclusion that the au 1 brake booster which is not sealed does not seal well enought to keep water out ..including degreaser or brake fluids from spillage out of the master cylinder.This a design safety fault of ford. Rubber will always be eaten by chemicals.It is the responsibility of ford to make these cars standards safe..not mine. Being brown in colour I am leaning strongly to water and degreaser seeping into the brake booster housing and eating the rubber away.However I cannot discount brake fluid spillage .But no brake fluid is brown.This looks like water...

Well I dont like saying things for nothing and scaring everyone.I have fully investigated my claim and found it to be true.The au 2 brake booster is a fully sealed unit and cannot allow the penetration of fluids into the booster.

The au1 booster is not sealed properly and it comes apart by unbolting 2 bolts. It is likely to be damaged due to liquid ingress and should be recalled and replaced by ford immediately!!!The join is where the problem is.
Why the second unit broke is a big mystery to me.I havent got it as I returned it to the wreckers under warranty.

I recommend that all AU1 drivers get their au 1 booster removed opened and checked for hardening of the rubber diaphram .If it is not present then I highly recommend that the unit is resassembled and then seal the join all the way around with a oil resistant silicone gasket glue.

Sorry to say that many of you were absolutely wrong.

If you look at my photos then you can spot where the diaphram cracked.

**Stav** · 19-05-2006, 07:57 PM

If I save 1 life then this thread was worth it.

**Stav** · 19-05-2006, 08:19 PM

Heck now I want compensation for loss of earnngs. :SaiyanSmi

AUXRVIII · 19-05-2006, 10:37 PM

I work as a tech in a Ford dealer & have done so before AU1 was released & I can say with hand on my heart that there have been no faulty brake boosters replaced on any AU falcons that I have been made aware of.
Any brake booster will have water/brake fluid enter it if the area is washed with pressure washer or good hose pressure due to the pushrod into the master cyl corroding &/or dragging fluids through past the seal, this is something that happened on my EB Fairmont with 110,000km's with a steel booster.

FRDGAL · 19-05-2006, 10:46 PM

Quote:

Originally Posted by useless

If I save 1 life then this thread was worth it.

Im going to get mine checked just incase. You know me, the panicer lol.

**Stav** · 19-05-2006, 11:05 PM

Quote:

Originally Posted by AUXRVIII

I work as a tech in a Ford dealer & have done so before AU1 was released & I can say with hand on my heart that there have been no faulty brake boosters replaced on any AU falcons that I have been made aware of.
Any brake booster will have water/brake fluid enter it if the area is washed with pressure washer or good hose pressure due to the pushrod into the master cyl corroding &/or dragging fluids through past the seal, this is something that happened on my EB Fairmont with 110,000km's with a steel booster.

Fair enough.I believe you .But whast has happened inthis instance is irrefutable.The leak is between the two casings at the join at 4pm.Also I will attempt to get the other broken booster back from the wreckers and open that. It just gets a bit uncanny. 2 faulty au1 ford boosters in 3 days.

No water marks were near the pushrod seal on this one.The casing rubber diaphram was destroyed by fluids

mik · 21-05-2006, 10:31 PM

i`m worried if you have extra vacumm from the the bigger booster it might make the pedal extra sensitive , watch that first brake application useless, maybe its a combination of things engine bay heat, contaminents,old age, personally i wouldnt buy brake parts from a wreckers who nows how many k`s that 2nd booster had on it, how many k`s has your au got on it at booster fail, ford will probably say the unit has done reasonable service

**FTE217** · 21-05-2006, 11:38 PM

useless why would you buy brake booster's from the wreckers in the first place ?
OK to save some $$ but arn't you meant to save yourself ? Maybe your your own worst enemy.
Second hand brake bit is asking for trouble if you ask me.

**Stav** · 22-05-2006, 12:01 AM

Can you get them new?

**FTE217** · 22-05-2006, 11:34 AM

Quote:

Originally Posted by useless

Can you get them new?

Ofcourse you can buy new but I'm sure the price is high coming from Ford.
Their is a good brake specialist called Brakepro in Parra off Vic rd. they would have recoed ones or may have more competitive pricing on a newy.

mash · 22-05-2006, 08:42 PM

I f you buy a 2nd hand car it comes with second hand brakes so i cant see the issue with using a booster from a vehicle of the same age as the one you have been driving. I have seen brand new (same age as old just been on a shelf) rubber products perish very quickly. the rubber strap that held my tank on my 2002 xr400. on 3rd one now.

**Stav** · 22-05-2006, 11:22 PM

Blue driver...I am a tight as--- Also I am more scared of recoed units.A bit of a phobia I have. I got new/reco lash adjusters from repco and they were noisier than the old ones for example.

**FTE217** · 23-05-2006, 08:12 AM

what do you expect from repco lol...remeber Rip Every Poor C--t Off hehe
I never buy from them.