Brake pressure regulator valve causing problems? Solved!!!!

[surfbus23]

We used some 1200 grit and what I was told was an aerospace surplus flat steel table to get nice flat surfaces. It seems to me that the rubber gasket is allowing fluid past it. Looking at other photos and my own, I'm also pretty sure it's a squared instance of rounded, so not even sure how one would replace it.

If I can't get it to stop leaking or find a working replacement, I suppose it's safer to bypass the thing all together?

[SGKent]

did you sand the halves on a quality belt sander or piece of glass to make sure there is no warp. I admit I was lucky. Mine was rusty and I just replaced it with a new one 15 years ago. You could find them then. Scott at German Supply might make a rebuild kit. I don't know. Sarcastically, it is only your brakes...
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"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[surfbus23]

I'm still having trouble getting this thing sealed up. Blew a hole in the .8mm gasket when I was adjusting the rear drum brakes and pressing hard down to recenter the pads. Thinking it was because we used too thick of a gasket (the clearance of the o-ring above the lip is minuscule), I made a .3mm one like stock. That worked great for a couple thousand miles, but I'm back to getting some leakage.

Any chance anyone has an open one and the measurements for the o-ring? I need to make sure I have a correct sized replacement if I'm going to take it off again.

Thanks!

Kevin

[lil-jinx]

traveling around the world in a vw bus.what a great adventure!
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https://www.thesamba.com/vw/forum/viewtopic.php?t=668799
1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy sold dec 2024

1974 parts bus
A smart man learns from his mistakes,a very smart man learns from other's mistakes.

[SGKent]

[surfbus23]

Good news. Via a French VW Facebook group I found a kind mechanic who was willing to set aside some time to help me. We pulled the thing apart and found the gasket had all but completely deteriorated in one corner. So much so that it had permitted the entry of outside dust into the regulator. We cleaned it up, fashioned a new gasket and got it back together and leak free.

As far as the paper gasket goes. My guess would be that the primary sealing duty is supposed to come from the rubber seal. It’s a square shaped circle seal (or at least mine had become square after 50 years) and with only a tiny amount of clearance so a thin paper gasket is about all that it can accept.

[lil-jinx]

i find it odd that there is a paper gasket between the parts,paper gaskets are not normaly used in hydraulic systems,orings yes and some times steel gaskets with built in o rings,
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https://www.thesamba.com/vw/forum/viewtopic.php?t=620186
https://www.thesamba.com/vw/forum/viewtopic.php?t=668799
1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy sold dec 2024

1974 parts bus
A smart man learns from his mistakes,a very smart man learns from other's mistakes.

[surfbus23]

Again, many thanks. I guess I have always assumed the leak was coming from the seam, but will give them a bit of a turn. Unfortunately, propane torch isn’t in the current kit.

[Abscate]

Make a bypass line up out of NiCopp and get that leak stopped, that’s dangerous to you amd others. You are probably loaded well enough to never actually use the regulator if you live in the Bus, but worst case shift as much weight as you can to the rear to help out brake equalization. Even a piece of flex line is better than a leak. Heat those flares with 30 seconds propane to get them off. If the break, don’t fret, NiCopp is an easy repair. No reason to drain fluid, remove and bleed at the repair. A bit messy, but also a good time to change brake fluid older than 2 years/40,000 km
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[SGKent]

[surfbus23]

Thanks for the helpful responses. 6 years living in the van and driving around the world. It is tough sometimes no doubt. I visited a VW mechanic in France and he just told me straight up no. He wouldn’t even discuss it.

I am worried about the possibility of getting stuck but I’m already headed that way as the brake reservoir is dropping at an alarming rate. Point well taken though and I’ll keep searching out help.

[lil-jinx]

if you are stuck you could bypass it,but you will need to be aware that the rear brakes may tend to lock up and skid the tires,reducing the braking effect.
to prevent losing the brake fluid,you can apply the brakes and hold the peddle down a little with a hold down tool (a stick will do if cut to length),this will cause the mc to block the ports from the resoirvoir prevent fluid flow,a bit of dum dum or the like will stop any minor drips at the brake line fittings.
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https://www.thesamba.com/vw/forum/viewtopic.php?t=620186
https://www.thesamba.com/vw/forum/viewtopic.php?t=668799
1974 Bay Westfalia. she likes to be called Ethel.
1968 Dune Buggy sold dec 2024

1974 parts bus
A smart man learns from his mistakes,a very smart man learns from other's mistakes.

[SGKent]

[surfbus23]

After years of very mild wetness my regulator has started to actively drip. I don't have a home base, so it's going to be a parking lot repair. Some questions:

What's the best way to get the brake fluid out before removing the lines from the regulator? I'm thinking just having a pan below it to catch whatever is there.
What should I use to clean the internals?
Should I use some gasket sealer in addition to the paper gasket I am going to craft? If so what kind?

Thanks! And any other tips/words of encouragement would be greatly appreciated.

[kreemoweet]

[SGKent]

look for witness marks
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"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[bruehoyt]

he paper gasket in my pressure regulator failed. I, like you, have been unable to find a rebuild kit. If anybody has any new information on gaskets or seals, they would be appreciated. The question I have is a washer. It doesn’t seem to be listed on the diagram. But it definitely fell out when I took thebody apart. Does this go between the spring and the primary piston?
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Current VW's:

71 Westfalia https://www.thesamba.com/vw/forum/viewtopic.php?t=633955

74 Super Beetle Convertible Sun Bug https://www.thesamba.com/vw/forum/viewtopic.php?t=748008

Past VW's:
71 Karmann Ghia Autostick. 17-21. https://www.thesamba.com/vw/forum/viewtopic.php?t=727596
70 Karmann Ghia driven 00-03, 67 Karmann Ghia 91-97, 74 Karmann Ghia 92-94, 71 Karmann Ghia 87-92, 74 Super Beetle 86-87, 71 Karmann Ghia 85-86 (my avatar)

[Loftus]

[SGKent]

Scott at German Supply has been doing the valves for years.
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"Most people don't know what they're doing, and a lot of them are really good at it." - George Carlin

[surfbus23]

My regulator is leaking at the seams. To fashion a new gasket is there a specific kind of paper that is needed or will any paper gasket material do the trick?