In order, the most common issues:
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#1. System vacuum leaks allowing dust and trash to enter the vacuum pump check valves.
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#2. Pump piston seal fails = allows engine oil to enter piston cylinder = oil coating check valves, system vacuum leaks allow dust and trash to build up on the oil coated check valves, eventually holding the valves open.
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#3. Incorrect rebuild, very common.
***
#4. System vacuum leaks allowing
ABRASIVE dust and trash to enter the vacuum pump cylinder, scoring cylinder walls into junk = impossible to repair as a DIY = send in for rebuild or scrap it.
**
#5. Bearing or piston arm failure.
Have a great day.
__________________
ASE Master Mechanic
https://whunter.carrd.co/
Prototype R&D/testing:
Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician.
Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
Vehicle build.
Fleet Durability
Technical Quality Auditor.
Automotive Technical Writer
1985 300SD
1983 300D
2003 Volvo V70
https://www.boldegoist.com/