Lancia Motor Club

Model Technical and Interest => Fulvia => Topic started by: simonpen on 27 February, 2021, 09:10:50 AM



Title: Bonaldi servo
Post by: simonpen on 27 February, 2021, 09:10:50 AM
Does anyone know of a company in the UK that could rebuild the servo from my Rallye S? Or recommend a suitable modern replacement?


Title: Re: Bonaldi servo
Post by: Richard Fridd on 27 February, 2021, 10:24:22 AM
I have been advised that 'Car Build Solutions' in Marden Kent have modern alternatives, which I will be interested in.


Title: Re: Bonaldi servo
Post by: andyps on 27 February, 2021, 11:40:12 AM
Past Parts - http://www.pastparts.co.uk/ - said they could do mine but when I sent it to them they tested it and said it worked properly so sent it back to me without charge. I was getting the calipers refurbished by them at the same time.


Title: Re: Bonaldi servo
Post by: lancialulu on 27 February, 2021, 08:47:52 PM
I have heard Omicron do this and have a test bench ....


Title: Re: Bonaldi servo
Post by: nistri on 28 February, 2021, 09:28:00 AM
On the rallye S the problem might be just bad rubber seals in the servo, replacement kits are available, Andrea


Title: Re: Bonaldi servo
Post by: pasey25 on 28 February, 2021, 10:47:37 PM
i just had mine rebuilt (and the master cylinder too).

it wasnt cheap (and I supplied the rebuild kits).

a bit frustrating


Title: Re: Bonaldi servo
Post by: nistri on 01 March, 2021, 08:26:58 AM
I understand your frustration. My experience is that at least on master cylinders (not corroded internally) apparently good seals actually are no good, Andrea


Title: Re: Bonaldi servo
Post by: Jaydub on 01 March, 2021, 08:47:07 PM
Hi Simon, if you have a workshop/garage it`s possible to buy the kit and rebuild it yourself. Mine was really bad and so I overhauled it myself.


Title: Re: Bonaldi servo
Post by: simonpen on 18 March, 2021, 02:45:10 PM
Update: I decided to send my servo to Omicron to let them rebuild it. This they have done but it required a lot of work and therefore time (13 hours), which is expensive. Generously they did not charge me the full amount; the reduced cost was still far more than I would have paid if I had known upfront what it would be, but as they rightly point out until you start a job it is difficult to predict what will need doing. My car is no concours contender and therefore, with hindsight, it would have been better to buy an aftermarket servo at around £300. I shall of course have forgotten this lesson when I buy my next car.


Title: Re: Bonaldi servo
Post by: lancialulu on 18 March, 2021, 04:45:22 PM
I am rebuilding a Rallye S remote servo at the moment and will write up for VL.


Title: Re: Bonaldi servo
Post by: AusFulvia on 18 March, 2021, 10:24:43 PM
I have my Servo in my Shed. It is not on the car as the Graham O"conner who restored the car and is a bit of a Fulvia Guru in Australia said I was just looking at trouble by fitting it.  I get an S1 S should have it on but the failure stories I have been told I can live with it not on it but available to the next keeper when I decide to sell


Title: Re: Bonaldi servo
Post by: lancialulu on 18 March, 2021, 11:06:35 PM
I have my Servo in my Shed. It is not on the car as the Graham O"conner who restored the car and is a bit of a Fulvia Guru in Australia said I was just looking at trouble by fitting it.  I get an S1 S should have it on but the failure stories I have been told I can live with it not on it but available to the next keeper when I decide to sell

I am afraid even without use it will have at least gummed up but may also have suffered irreparable corrosion due to the hydroscopic nature of residual dot 4 fluid.....


Title: Re: Bonaldi servo
Post by: dhla40 on 19 March, 2021, 08:18:28 AM
Hi Jaydub

What technique did you use to seperate the servo body? I have a spare to recondition but have been put off by the heavy duty crimping holding it together.

Sean


Title: Re: Bonaldi servo
Post by: Jaydub on 19 March, 2021, 11:20:34 AM
Hi Sean, I clamped it in the vice where the 2 Master cylinder studs are, soaked the area in penetrating oil where the crimped join is, for a few days. I then drilled a piece of wood to fit the 4 studs where the aluminium housing bolts on, it needs to be about 4 feet long to get enough leverage. I then put a ratchet strap around the complete assembly to contain the very strong spring, BE CAREFUL!, and turned the top part to align the cut outs in the body and it sprung apart. Be warned it was very hard to twist at first due to corrosion and the friction of the rubber seal.

Jaydub.


Title: Re: Bonaldi servo
Post by: Richard Fridd on 19 March, 2021, 12:28:08 PM
I have my Servo in my Shed. It is not on the car as the Graham O"conner who restored the car and is a bit of a Fulvia Guru in Australia said I was just looking at trouble by fitting it.  I get an S1 S should have it on but the failure stories I have been told I can live with it not on it but available to the next keeper when I decide to sell

         What is the result of having 'it not on' ?  Increased peddle pressure required I expect. Is this the same as disconecting the servo vacuum hose? I ask as I have to decide whether to repair, replace or now that you mention it, leave my suspect Flaminia servo disconnected. Has anyone here fitted a larger bore master cylinder? I don't remember a servo on my s1 Fulvia Sport. Richard


Title: Re: Bonaldi servo
Post by: lancialulu on 19 March, 2021, 12:50:51 PM
I have my Servo in my Shed. It is not on the car as the Graham O"conner who restored the car and is a bit of a Fulvia Guru in Australia said I was just looking at trouble by fitting it.  I get an S1 S should have it on but the failure stories I have been told I can live with it not on it but available to the next keeper when I decide to sell

         What is the result of having 'it not on' ?  Increased peddle pressure required I expect. Is this the same as disconecting the servo vacuum hose? I ask as I have to decide whether to repair, replace or now that you mention it, leave my suspect Flaminia servo disconnected. Has anyone here fitted a larger bore master cylinder? I don't remember a servo on my s1 Fulvia Sport. Richard
Richard your S1 Sport was half the weight of your Flaminia.......


Title: Re: Bonaldi servo
Post by: nistri on 19 March, 2021, 04:08:26 PM
Remote servos were also fitted to contemporary Alfa Romeo Giulias and therefore should be readily available as new parts. The only slight difference is the mounting bracket but this can be simply solved. Andrea


Title: Re: Bonaldi servo
Post by: lancialulu on 19 March, 2021, 05:35:08 PM
Remote servos were also fitted to contemporary Alfa Romeo Giulias and therefore should be readily available as new parts. The only slight difference is the mounting bracket but this can be simply solved. Andrea
From a bit of desk research the Alfa unit seems to have a different air valve diaphragm housing and entry exit hydraulic connections. The alfa parts list shows different castings etc but looks like internal parts could be mostly the same. The Lancia unit has an unobtanium (almost) rear cup seal of 7x16x5.3. Also the push rod which is almost certainly corroded at the sealing point is only available from Cavalitto as afar as I know.


Title: Re: Bonaldi servo
Post by: nistri on 19 March, 2021, 07:48:20 PM
Just for the record I am using an Alfa servo unit on my GTE for the past 22 years without any problems so far, Andrea


Title: Re: Bonaldi servo
Post by: Jaydub on 20 March, 2021, 11:32:01 AM
Sean, I forgot to mention that it is important to clearly mark the 2 halves before separation as it governs the orientation of the master cylinder/ reservoir. Make a careful note of all parts and relevant locations.  Re assembly...... after cleaning and before plating of the halves, do a dry build without the spring, to make sure that you can twist the halves after aligning the cut outs. It will require some filing of the surfaces/edges due to corrosion build up. Lubricate the diaphragm with rubber grease to aid twisting motion. It is a bit tricky because of the thickness of the new diaphragm and having to compress the spring at the same time.
You can get all the parts from " Pieces-Fulvia" in France.
If you require any more advice or photo`s let me know.
Good Luck!

Jaydub.


Title: Re: Bonaldi servo
Post by: dhla40 on 21 March, 2021, 09:07:18 AM
Thanks Jaydub

Sounds like I have a new lockdown project.

Sean


Title: Re: Bonaldi servo
Post by: simonpen on 07 October, 2021, 06:36:36 PM
My rebuilt S1 servo has just failed after approx 500 miles. A fair bit of brake fluid being sucked into the vacuum pipe and leaking from there onto the floor. An obvious lesson there methinks. Has anyone fitted a different make aftermarket servo to a Rallye S?


Title: Re: Bonaldi servo
Post by: lancialulu on 07 October, 2021, 07:45:47 PM
who rebuilt it? did the push rod get changed?

Not sure if anyone has plumbed in one of these...

https://www.carbuilder.com/uk/compact-remote-brake-servo-single-circuit-booster-assister


Title: Re: Bonaldi servo
Post by: Richard Fridd on 07 October, 2021, 07:54:47 PM
I have fitted the Carbuilder Solutions dual circuit servo to my Flaminia recently. Richard


Title: Re: Bonaldi servo
Post by: simonpen on 17 October, 2021, 06:59:13 PM
I will at some point fit either the Carbuilder one or more likely a later Bonaldi (type). but for now I shall re-plumb her to go without.  As much as the £700+ wasted  is a pain, the time wasted and inconvenience is bloody annoying. 


Title: Re: Bonaldi servo
Post by: simonpen on 19 October, 2021, 04:16:37 PM
Re-plumbed and bled. I don't know what the servo was doing but the pedal is firmer and the braking as good if not better. I shall not bother to replace the servo.


Title: Re: Bonaldi servo
Post by: fay66 on 20 October, 2021, 04:36:42 PM
Re-plumbed and bled. I don't know what the servo was doing but the pedal is firmer and the braking as good if not better. I shall not bother to replace the servo.
None fitted to my Series 1 2c Berlina, always a firm pedal and have to push firmly, never had a problem, and never felt the need for a servo.
Brian
8227 8)


Title: Re: Bonaldi servo
Post by: Richard Fridd on 20 October, 2021, 04:57:53 PM
Do the servo and non servo systems have different sized master cylinder bores to compensate, or other methods of leverage?


Title: Re: Bonaldi servo
Post by: simonpen on 20 October, 2021, 05:21:21 PM
My (new) master cylinder  is a 19mm type.


Title: Re: Bonaldi servo
Post by: nistri on 21 October, 2021, 07:50:16 AM
S1 Fulvias normally have 18 mm master cylinder, the 19 mm is for GTE and rally S, Andrea