Expert Hdi - Front Brakes Binding

[BigJohn]

I have seen this on other forums, front brake binding after fitting new discs and pads... what is the cause of this? Brake Servo Faults/ Master Cylinder faults, any ideas?

[davidireland]

Whoever fitted the brake pads and discs did not pump the pedal up after doing one side and then pump it up again after doing the other side.
The servo will need adjusting or a new servo and master cylinder.
Have seen it before. nightmare of a job to do a servo one one of those.

[BigJohn]

What adjustment are you mentioning there davidireland and what is the proceedure for changing the servo, is there a scematic for this?
Many thanks for your reply and help,

[davidireland]

The internal rod in the servo can be adjusted in and out. I wouldn't recommend it though. It should work the way it is.
I would always recommend replacing the servo.

In fairness you could also have a caliper problem. Get them checked first..

[BigJohn]

The calipers apear to be free and the pistons returning OK. Is there a proceedure for removal and replacement of the servo unit?
Many thanks for your assistance davidireland.

[davidireland]

Its an absolute nightmare. Very nasty job. Ive done two. If your van is a hdi then its harder.
The servo is mounted on a plate which inturn is attached to the bulkhead. There is a pin holding on the servo rod a the the back of all this lot which you'll need some fair small hands to get it out.

[BigJohn]

Oh yes its an 2.0 16V 110ps Hdi, 2004 model (54 plate, UK), sounds like a real laborious task changing a servo on the Expert, but I guess if it needs doing, it needs doing.
It's very strange that by changing pads in a certain way can cause a servo fault to kick off, I have heard of Audis and Skodas having servo issues, must be something that causes it.

Oh well, here goes...