Brake Servo non return valve broken nipple fix

Hi all,

Having owned my golf less than a year and needing to replace the valve due to broken nipples I looked into seeing if there was a fix.

3 reasons really,

1. cost of buying new ones, second hand you're talking £20+ and new £25+
2. these seem to be getting less common to find
3. lots of people seem to have had same issue as the nipples are brittle as hell.

What you will need:

Dremmel (or cheap alternative)
new nipple (link below)
m6 bolt or tap
drill
2mm, 3mm, 4mm & 5mm drill bits
flathead screwdriver for jubilees
patience and care

so here is the offender (without the t-piece)…



I was luckyish with mine as I could still get some sort of connection with zip ties but looked naff as hell.



had a quick search on tinterweb and came across these from forge motorsport for nifty price of £1.98
link




once the part has arrived, simply disconnect the valve, id advise leaving the main pipe to servo attached and remove from servo its self as the pipe can be a bit of a pain to take off.

once removed, dremmel broken nipple off if any sticking out




if bottom nipple like mine was you will need to carefully dremmel the area flat to allow space for new nipple, watch you dont catch other nipple if you have the GTI version with 2






drill new hole, due to old brittle plastic I started with 2mm and worked up to 5mm, slow drill as it may bite hard and snap plastic



I didnt have my taps at hand so i used an M6 bolt to create thread in the hole, once done simply twist in the nipple, I did have to use pliers to grip so wrapped in insulation tape, did take bit of the black paint of but hey ho




once done, refit, if cold pipe you may want to open vacuum pipe hole slightly by drilling, lots of meat on pipe so easy enough to do, dont go too big or you wont get a tight enough fit….


saving of £22 ish quid

Cool, I like….

new are made in Germany for Cadillac Cimarron's.

Cheers bri, yea saw them but you're talking £25 then gotta get a t-piece too.

Just thought I'd save couple quid 😂

H3LTER said

Cheers bri, yea saw them but you're talking £25 then gotta get a t-piece too.

Just thought I'd save couple quid 😂

Oh, I don't have any problems with cost effective repairs….

I just know that on older plastic to treat it like it is very very fragile…. I guess that is why we call the hard plastic  brake line from the servo to the TB the "Crack Pipe" as it cracks when you man handle it.  Rule number 1.  Always cut the hoses off of plastic bits pulling leads to breakage.
Rule number 2.  Remember rule number 1.
 

Great Mod H3LTER

Thanks !

Hi this has just happened to me broken nipple trying to remove a stuck coolant pipe ,any one got a part number or link for the full new one as im struggling to get a part number ,il buy the full pipe if need be thanks