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Sabre

Ineffective brakes on a 300TDi D1

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My son recently returned from a trip with his TDi D1, and had virtually no brakes when he arrived home. First thing we did was to bleed the brakes, but it made no difference.

We then replaced the brake booster with a brand new one, bled the brakes, no improvement

Because the vacuum pump was leaking oil again (after we fixed it a few years ago), we installed a brand new vacuum pump. Still no brakes. we bled the system again, and a few air bubbled did come out, but there was no improvement. We are now in a dead end

Advice needed (and appreciated 👍)

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What's the pedal like?

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When you press the pedal, does it drop on start up?

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last time i had this issue on a d1 it was the pushrod length. if you take the m/c off, stick a bit of blue tack to the end and bolt it back on (don't touch the pedal) then take it off again youll see the clearance. you want the clearance to be about the thickness of a sheet of paper. 

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19 hours ago, Bowie69 said:

What's the pedal like?

The pedal feels quite normal; goes down a bit then solid. You then have to press it really hard to bring the vehicle to a standstill

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2 hours ago, Daan said:

When you press the pedal, does it drop on start up?

Nope, I checked it, and the pedal does not go down upon start-up

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1 hour ago, Sabre said:

Nope, I checked it, and the pedal does not go down upon start-up

That means your booster does not work as it should. On a defender there is an o-ring between the booster and the master cylinder which can leak. Not sure if a disco has got this, but it may be worth checking.

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1 hour ago, Daan said:

That means your booster does not work as it should. On a defender there is an o-ring between the booster and the master cylinder which can leak. Not sure if a disco has got this, but it may be worth checking.

Thanks Daan. We installed a new booster with a new O-ring

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