Club 80-90 Forums

On the way back from the Big Chill festival a couple of weekends ago, we had brake failure, with the brake pedal going almost straight to the floor (along with my heart I might add) with just about no braking capacity at all. Fortunately we were on quiet country road and avoided a potential nasty accident.
Turns out both back brakes were cooked (you could smell that burnt linings pong) and with the assumption that the brake fluid had boiled.

Anyway, after being jolly glad to be alive, I have since given the brakes a thorough once-over, with no faults found at all. Bleeding the brakes has restored them to full capacity.

The only conclusion, embarassingly, is that I must have left the handbrake on, partly at least (the van is so gutless that if you leave it fully on you don't go no-where at all, although even partly on the extra drag is usually really noticable).
We are not blessed with a fancy handbrake warning light (the light position on the dash is blanked off), so the question is, does the standard wiring loom have all the connections so the handbrake and low brake fluid warning light be retro-fitted? Also, how does the switch fit to the handbrake and where does the connection terminate on the loom?

If it can be retro-fitted, it might stop any future heart-stopping moments. Mind you, I'm probably going to check the handbrake a hundred times on each journey from now on anyway.

Thanks in advance for any assistance.

We are not blessed with a fancy handbrake warning light (the light position on the dash is blanked off), so the question is, does the standard wiring loom have all the connections so the handbrake and low brake fluid warning light be retro-fitted? Also, how does the switch fit to the handbrake and where does the connection terminate on the loom?

Can't be specific about an '85 model as mine is '86 and the fuse setup changed about then.

The Haynes wiring diagram, which they say is 'Typical' seems to be for post '85 models and shows the feed for the warning light taken from fuse 18 (10 amp) to one side of the warning lamp, then one wire goes to the live side of the reservoir level switch, other side of the switch to earth.
A second wire goes to the handbrake switch which earths when the handbrake is in the 'UP' (ON) position.

On mine the handbrake switch looks identical to the door operated courtesy switches for the interior lights. It sits under the handbrake lever near the pivot (you have to remove the plastic trim to get at it).
Should be easy enough to find a suitable fused ignition switched live on your setup and run a wire or two. (Adding an inline fuse is usually a good idea).
My handbrake switch wire runs from the dash area under the cab carpet.

P.S. I would recommend changing your brake fluid ASAP. See this thread.........https://club8090.co.uk/forum/viewtopic.p ... &p=7393629" onclick="window.open(this.href);return false;

Mike

Good information, many thanks, including the important brake fluid maintenance reminder. It is due as we changed it when we got the van 3 years ago.
Although if I did leave the handbrake partly on (remember: innocent until proven guilty) I guess the fluid would go 'off the boil' at some point anyway, if you pardon the pun.

I assume the handbrake switch has some sort of mounting clip/bracket?

Thanks again

I assume the handbrake switch has some sort of mounting clip/bracket?

As far as I remember (it was 9 or 10 years ago!) the switch was attached directly by its outer flange to the metal floor of the van, by one (or two) screws which also provided the earth point. It was probably sitting in a hole in the floor. Very primitive switching arrangement!
Have a look at your door light switches, same sort of thing.

vagcat.com says...........(part number.... 113947561H.... Handbrake switch)

BASIC GERMAN PRICELIST
Partnumber Title Price
113947561H SCHALTER 3.5 Euro


Mike

Appreciate the extra info.

Meanwhile - manual handbrake and fluid level checking - only properly this time.

hi mate,we did a run down france a couple of years ago and had an exact same prob with the brakes,pedal went flat to the floor and i bricked it! anyways, left her to cool down luckily on a camp site at the foot of a mountain after accidently driving throught the centre of lyons's well placed traffic lights!,checked the levels etc all ok,only thing i have done since is get rid of the plastic type wheel trims and put original dub ones on that dont cover the vents in the wheels!,did 3.5k europe last year and 2.5k last week without any brake probs at all,and still havent changed the fluid since i bought her three n a half years ago! maybe im just lucky but hope this helps. leroi

Have you got a front spoiler?
This can disturb/block the airflow to the brakes and cause them to cook. Had an aftermarket spoiler on my '88 1.9 petrol and took it off after the brakes cooked during descending two Swiss mountain passes in sucession.
I love the smell of cooked brake pads in the afternoon - not.

Good tips guys, but we're on standard hub caps and no spoiler.

Many moons ago, I had to explain to my first wife (as we descended a steep mountain in Wales) that using the brakes to slow herself down for extended periods was not a good idea. Horrible hearing the engine whine using the gearbox as a brake but better safe than sorry. They can get very hot very quick.

I hope the whole brake fade/engine braking/wrong gear selected wasn't the last straw with your first wife?!

No doubt these big old vans do suffer from it, particularly downhill, but I'm 'happy' to say our brake failure was on the flat on a quiet county road approaching a bend, so the assumption is mechanical and/or possible dunce behaviour regarding the handbrake, as above.

And I was driving, so I can't blame the better half.