VW Crafter: Brake Pedal Vibration Points to Rotor Wear

I had a very similar issue with my 2008 VW Transporter T5 diesel. With some experience working on vans, I recognized these symptoms immediately as they match what I dealt with. The pulsating brake pedal and spongy feeling often points to issues with the hydraulic brakes system, but in my case, an undervoltage problem was actually causing irregular signals to the brake control unit. Metal brakes and rotors were initially suspected, but after proper diagnosis, it turned out the electrical system was the culprit. My workshop ran a full diagnostic check and found the voltage issue was affecting multiple systems, including the brake fluid pressure sensors. The complete fix, including labor and parts, cost 240€. Since the repair, the brake pedal response returned to normal with no more vibration or sponginess. Before jumping to conclusions, could you share: Current mileage on your Crafter, When was the last brake fluid change, Are there any warning lights on the dashboard, Does the issue happen more when the engine is cold or warm, Have you noticed any other electrical issues like dimming lights This information would help determine if your issue matches what I experienced with my Transporter or if you might be dealing with actual brake rotors wear.

Thanks for sharing your experience. My Crafter just hit 85800KM and had its last service 3 months ago. The symptoms do sound similar, but I am not seeing any warning lights or electrical issues. The brake pedal vibration happens consistently regardless of engine temperature. During the last service they did check the disc brakes and brake fluid levels were fine. This makes me think my issue might be more mechanical than electrical. The pulsating through the brake pedal seems to suggest uneven wear on the brake rotors. Getting more pronounced when applying firm pressure to the pedal. Might be time to have the brake rotors inspected and possibly replaced if they are warped or worn unevenly. Would it be safe to drive it to a workshop about 30 minutes away or should I have it towed to avoid any risks to the brake system?

Thanks for the additional details. Based on your description, this does sound more like a mechanical issue with the brake rotors rather than the electrical problem I experienced with my Transporter. The consistent pulsation regardless of temperature, combined with increased feedback under firm pressure, strongly suggests warped brake rotors or uneven wear patterns on your disc brakes. This is quite common at your mileage point, especially if the van handles frequent stops with heavy loads. Regarding your workshop trip, while worn brake rotors are concerning, your brake system is still functioning. Since you can feel the pedal response and the brakes are still working effectively, driving 30 minutes to a workshop should be manageable. Just maintain extra following distance and avoid harsh braking. For reference, when I replaced my brake rotors and brake pads last year, the complete job cost around 380€. The workshop also recommended resurfacing the rotors first to check if that would solve the issue, which can be a more cost-effective solution if the wear isnt too severe. When you visit the workshop, have them check both front and rear brake components, as uneven wear on either set can cause these symptoms.

Thanks for all the input. After considering the feedback, I will drive carefully to the workshop tomorrow morning when traffic is lighter. The symptoms match worn brake rotors more than electrical issues, especially since there are no warning lights or other electrical problems. The consistent vibration through the brake pedal during braking, regardless of temperature, has me convinced the disc brakes need inspection. Will have them check both the brake rotors and brake calipers to ensure nothing else is contributing to the uneven wear. Based on the cost shared, I am budgeting around 400€ for potential brake system repairs. Will take it easy on the drive there, keeping extra distance and avoiding sudden braking. Better to get this sorted now rather than risk more serious brake issues developing. Thanks again for helping me understand the likely cause and giving me confidence about safely reaching the workshop. Just one last thing, is it normal for brake rotors to need replacement at around 85000KM? Want to stay on top of maintenance intervals going forward with my Crafter.