for about 2 months I have been at war with my vacuum pump. The first time I rebuilt it, it failed within 2 weeks. I rebuilt it again Yesterday and it seems to be failing already. The rebuild kits I have ordered do not come with any instructions, or technical data regarding the replacement of the pump diaphram. I will try to contact the manufacturer of the kit on Monday (today is Saturday), to see if they can send me data/ instructions.

I must say that it is very disapointing that re-building a part as simple as this vacuum pump is giving me so much trouble. I have searched through dozens threads, but have only been able to find instructions for rebuilding piston type pumps.

Hopefully the manufactruer will be able to provide instructions, otherwise I'm just going to have to replace the entire pump...

I'm guessing that you torqued that little bolt in the center of the diaphram too much. I dont have the exact torque # but its not much and be sure and use the thread lock they supply, but not too much torque.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

Yea Stevo, That's what I figured too. I barely snuged the center bolt this time by keeping my "tightening hand" on the head of the wrench, and tightening barely past the point where the bolt seated. I am certain, however, that the pump failed the first time I rebuilt it because I did over torque that bolt (as was evident by the massive tear in the diaphragm.)

Have you had any luck rebuilding this type of pump? If so, in which direction did you install the diaphragm? I'm kind of grasping at straws at this piont!

Thanks for the response,

Jaden

I thought I had until a couple of weeks ago when one I did 25K ago, failed. I thought I hadn't over tightened that little bolt, but thats where it failed I dono ....I dont have a torque wrench that goes that low.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

You can always use my method; wait until it explodes, taking half the engine with it. Oops.

Was there any warning or the big KA BANG?

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

No warning that I could hear. I had been driving several hours at 80-85 mph and the vacuum brakes were working fine, then KA BANG. It wasn't a diaphragm failure, as far as we can tell the steel "rocker" inside the pump just broke.

Oh, thats a little scary. I always look at the bearing and see that nothing "looks" worn, couldnt say the belt was tightenen too much on that one

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

I think it was just 300K miles worth of metal fatigue. I guess it needed replacing anyway, but I could do without the collateral damage.

Yah, theres no way to tell that was coming.

I have one of those pumps on my "79" ("80" eng) and think I will switch it out for the newer type like the one on my other "keeper". I think there both good pumps but the newer style wont destroy your engine, dont think so anyway

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

Well, I'm in the process of getting a new vacuum pump, timing chain, tensioner, and valve cover. (that's all, as far as I know, but I haven't gotten today's revised cost estimate yet )

Sounds like a good spring project, I assume this Isn't the engine that ate the vacuum pump arm

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"