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Brake Issue (Clutch related?)


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Hi, I have a 2005 Ford Transit Connect T220D. For some reason the other day I went to park up and the brake pedal went really hard and no braking power. Managed to stop, just. Drove round car park a few times, still the same. Had to set off again but back on the road it was all fine. I stopped again to check (another car park) and it did the same hard pedal routine. When I set off back up motorway again it was fine. Got up to 60-70 mph , pressed brake, all good, but if I pushed and held the clutch in and freewheeled it was rock hard again, released clutch and was ok. So basically if I have clutch pedal in the brake pedal goes hard and loses like any servo assistance. I've checked pipes and can't see anything obvious. If I start the engine from cold the brake pedal is hard and doesn't depress slightly like you would expect. I appreciate it could be the vacuum pump but why does it work ok when clutch is not used? Any idea's? Anyone had similar? Cheers

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35 minutes ago, G B L said:

The US does not have the diesel version.  How is the vacuum pump driven? could the clutch linkage be hitting something when  engaged? Any pictures of the booster and clutch pedal layout?

When I start van from cold, with it in neutral and not touching the clutch the brake pedal is hard then as well, so won't be anything on the clutch linkage I suspect. Just tried it again and this time just knocked it in to neutral as I came in to park (not touching clutch) and it went hard again, so its actually working when in gear  and obviously not when in neutral/clutch in.

Edited by LakeDistrictPaul
added info
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Any chance of a Vacuum diagram? We have little access to any literature on the EU Models. If the brakes are normal with it in gear something is switching the booster off when either the clutch or the shift linkage is moved.

Any chance of pictures and more information?

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