boxer brake compensator set up

[citronut]

this in a 53 plate Boxer, it failed the MOT on insufficient pressure to the rear service brakes,

when i got under there it looked to me that someone had bin playing around with the compensator, the valve arm was fully pushed against the valve body, and a cable tie had been fitted around the push rod at the valve side of the actuator arm, this appears to have been stopping the push rod coming out of the arm,

i purchased a new valve from Peugeot at best part of £200 squid , as the three motor factors i tried say it was not listed at there suppliers so main agent only,

it comes complete with the push rod, springs, push rod mounting bracket that mounts on rear axle and a large red plastic thing wedged on the push rod at the valve side of the actuator arm, this looks like a setting up gauge/tool,

at the axle braket end of the push rod there is a sliding collar withy a grub screw with a 10mm hex head to clamp it to the push rod at the right point

has anyone got any idea on how to set this thing up,

i have spoken the my local dealers technician who is going to email me with set up details, as he said he thinks they have never fitted one,

[spider]

I've never fitted one, and I don't know anyone who has. Hmm.

I think you're (supposed) to have a certain weight in it and then use a pressure gauge in the brake line (so you can adjust the compensator to get the desired pressure), although I could be wrong.

Although drastic, A glace at one in the breakers to measure the length of the rod etc might provide a base setting if nothing else.

[citronut]

thanks for your reply Andy

i have now received the email from my local pug dealer and it basicaly states exactly as you say,

there is a unit with two pressure gauges mounted in it, you connect with a union one in the front flexi to caliper line, and one in the rear flexi to rear axle line,
then theres a large device that you attach between the chassis and back axle with a load gauge,used to load the rear axle,


trouble with looking at one in a breakers yard is you wont know if its been tinkered with by previous owners,

the original one on this van certainly had,

i can even make an educated guess as to were to set it, as for full circuit pressure the lever on the valve has to be hard against the valve body, theres no springs to hold the arm away, then nout to stop the rod falling out of the arm if left slack

[citronut]

i spoke to my local Pug dealer today asking how muchy they would charge to set this compensator up if we had to,

they say they cant do it as they have not got the special tools required for the job,

i thought/would have expected PSA to have a tool library but not a chance

[spider]

i spoke to my local Pug dealer today asking how muchy they would charge to set this compensator up if we had to,

they say they cant do it as they have not got the special tools required for the job,

i thought/would have expected PSA to have a tool library but not a chance

They do. It used to be (it probably is the same) some tools were compulsory and the dealer *had* to purchase them. Others could be rented from PSA, probably for a cost. One that springs to mind on Boxer's was some kind of adaptor for a DTI for the wheel bearings from what I recall.

They can hire the tool from PSA if they want, but its a bit of paperwork exercise involving the parts and service departments which may well be why they said they cannot. It used to be similar for E.F as in theory they would not have to pay VOR on exhausts but the reality was you did, then claimed it back.

[citronut]

i just guesstimated how to set thing thang up,
i i fitted it then locked the sliding collar off with all the free travel in the shaft/push rod taken up, then pulled the plastic block/gauge thingy out,
which as far as i can see is the basic/initial setting up procedure,

took it back for the re/re test and the readings on the rollers were almost double that of the first go round, so a PASS YIPPEEEEEEE,

obviously without running through Peugeot's long winded setting up procedure with lots of specialist equipment my local dealer dose not have, there is no way of telling if it is set correctly

[RichardW]

Sounds OK Malc - the real risk is you get it overbraked, such that when it's unloaded the rear locks up and comes round to meet the front if you brake downhill (or rolls it over!). Less of a worry if it's got ABS

[citronut]

Sounds OK Malc - the real risk is you get it overbraked, such that when it's unloaded the rear locks up and comes round to meet the front if you brake downhill (or rolls it over!). Less of a worry if it's got ABS

this is exactly what i told the customer Richard,

also in a discussion with the MOT tester
he said they cant test for this on the MOT brake rollers as ideally they require each wheel to lock out on the test,

as i said earlier

the new compensator comes with a red lump of plastic clipped onto the rod at the valve body side of the valve actuator arm,
this looks like it is a set up gauge to be removed one the sliding collar has been set/adjusted to take up any free movement in the rod,
once the clip is then removed it should give the desired free play/movement in the rod, which in turn dose not hold the valve at its fully open position