Power Brake Vacuum Assist Failure on Diesel Vehicles

[pjpvi]

Thanks to this thread, a sudden issue in changing airflow to different vents, realizing my van is at around 76,000 miles and 10 years old, and an upcoming trip that will take me deep into Canyonlands Maze District, I decided to replace my vacuum pump before it died on its own at an inopportune time.

... and, thanks to Todd's (Photographix) post, I decided to do it myself. Like Todd, I didn't remove radiator or shroud and had to trim one of the shroud fins just to maneuver the pump in and out. The project took a healthy chunk of the weekend, but am glad I did it to learn more about the engine and how it is put together. If I were to do it again, I could easily shave a few hours off the project.

Assuming my time is worth nothing, cost was $161 for Motorcraft pump and ~ $60 in specialty tools for total of $221.

Wow, what a project, but it's done and I'm glad it's now behind me.

Phil

[BogusBlake]

Originally Posted by pjpvi

Thanks to this thread, a sudden issue in changing airflow to different vents

That's a good symptom to keep an eye out for.

Originally Posted by pjpvi

$60 in specialty tools

What were the special tools you had to buy?

[pjpvi]

pjpvi wrote:
$60 in specialty tools


What were the special tools you had to buy?

1) Crappy Chinese made belt tensioner tool. Stripped at the joint at slightest pressure, so I just welded it in the position I needed it.

2&3) Pulley puller and installer for vacuum pump pulley. Had to grind down the puller so it would fit in the groove.

4) 1/4" drive "u-joint" to get that 3rd miserable bolt out. (it is good to have a combination of different length 1/4" drive extensions to get just what you need for each bolt)

[flyfisher]

Well I guess I can join this exclusive little club. My SMB is 10 years old, with 70,000 miles on it. Going over Snoqualmie Pass this morning on the way to a much anticipated fishing trip, a very faint ratcheting noise started. Sounded like it was from somewhere under the dash.

It didn't sound serious, and my only concern was that it was going to drive me nuts all the way to Idaho. 25 miles later, I took the long slow exit to Cle Elum and discovered I had no brakes.

I have AAA extended coverage, and it paid to get The Van trucked back to Seattle to get fixed. I guess I was lucky, very lucky, that it happened when I didn't need the brakes for anything. It's pretty hard getting 10,000 pounds stopped without that vacuum assist.

Tom

[pinz712]

Last month mine went out on my '08 at around 132,000. Had it towed 50 miles home. Told them to check the pump, they told me it was my booster and I "with all due respect check the pump". When I picked it up the mechanic had written an apology letter. Thanks to everyone who had this happen and posted it, saved a lot of hassle and time.

[Zeta]

I upgraded to an 06 E 450 Hydroboost system and master cylinder. Works well, even brakes a little better. I also, however, replaced the vacuum pump.

Z

[JoeyNick]

My vacuum pump went out at the 6 year / 101,000 mile mark. No warning, no noises. One second the brakes were fine, the next second it was like stomping on rocks. I'm glad I was only going about 15 miles an hour when it went out.

Naturally, it was around 7PM on Friday July 01, a three day holiday weekend and I was several hundred miles from home.

The brakes still work but it'll give you quite the leg workout.

[PatO]

But if you don't know about it beforehand (like me) you don't know if there is something that is going to be ruined or something is locked up and going to burst in to flames. Anything abnormal on this vehicle just gives me the willies.

[JoeH]

Can anyone confirm that this is the part # for the vacuum pump? 4C2Z-2A451-AA

[PatO]

The Brake Booster Vacuum Pump on my invoice is AC2Z2A451A - 2004 E350; $231 (a nice $65 profit for the shop!)

Just found this

Part No. 4C2Z-2A451-AA
Part Description PUMP ASY - VACUUM
Replaced By AC2Z-2A451-A