Ian_Fearn Posted March 17, 2012 Share Posted March 17, 2012 Hi there, I hope this post is in the right place...! I've got a 1995 300TDi Defender 90 thats done 160,000 miles. I've just replaced the front brake calipers due to a) a bleed nipple sheared off and b) pulling to one side during braking. I've got the calipers on and bled the system through 3 times but problem is that the brake pedal travel is a good bit more than it used to be. I'd say its between 1/3rd and half way down when the pedal goes rock hard. Its really disconcerting to drive compared to how it was. Pads and discs are existing, done about 5000 miles and in perfect condition. When pressing the pedal the front pads lock onto the disc but when the pedal is released the pads seem to be very loose in the calipers (both sides). Is this normal? On other cars, i normally expect the pads to stay relatively firmly against the side of the discs when the pedal is released. I think this could be what's causing the excess travel on the pedal. Anybody got any thoughts?? Many thanks, Ian Quote Link to comment Share on other sites More sharing options...
Les Henson Posted March 18, 2012 Share Posted March 18, 2012 The pistons and pads shouldn't really move away from the disc at all - merely stop pressing on it, so that if you turn the disc by hand there will be a rubbing noise as the pads are still lightly touching the disc. Sounds like something is sucking the fluid back - perhaps a master cylinder problem. Les. Quote Link to comment Share on other sites More sharing options...
Ian_Fearn Posted March 18, 2012 Author Share Posted March 18, 2012 Les, many thanks for your reply. The pads are definately withdrawing from the disc. I have read that the bleeding process can cause an old master cylinder to finally give way due to moving the seals further than they have for probably many years. Do you think this is a real possibility? Regards, Ian Quote Link to comment Share on other sites More sharing options...
bushwhacker Posted March 18, 2012 Share Posted March 18, 2012 Hi You don't say how you bled the brakes, I all ways find the 2 person method is the best. Quote Link to comment Share on other sites More sharing options...
Ian_Fearn Posted March 18, 2012 Author Share Posted March 18, 2012 1 person on the brake pedal, the other at the caliper. Used a one way valve. Quote Link to comment Share on other sites More sharing options...
Sirocco Posted March 18, 2012 Share Posted March 18, 2012 which brake calips did you replace them with? do you have a part number? Quote Link to comment Share on other sites More sharing options...
Ian_Fearn Posted March 18, 2012 Author Share Posted March 18, 2012 SEB500440 and SEB500450 Non-vented discs, they were in Britpart boxes but very clearly Lockheed parts (you can blatently see where all the lockheed and AP logo's are ground off) Quote Link to comment Share on other sites More sharing options...
Sirocco Posted March 18, 2012 Share Posted March 18, 2012 I was just wondering if you may have been sold vented calipers. I have a spacer kit hanging around and its probably 6-8mm thick from memory? worth measureing to see if your old calipers are any different. G Quote Link to comment Share on other sites More sharing options...
Ian_Fearn Posted March 18, 2012 Author Share Posted March 18, 2012 No, the calipers are definately the same as my others. I know about the spacers and theres none fitted. Quote Link to comment Share on other sites More sharing options...
Ian_Fearn Posted March 18, 2012 Author Share Posted March 18, 2012 For the relatively small cost of a master cylinder i've bought one. I'll post back if it sorts the problem. Quote Link to comment Share on other sites More sharing options...
Disco-Ron Posted March 18, 2012 Share Posted March 18, 2012 not wishing to teach anyone to suck eggs, but you do have the bleed nipples at the top don;t you...????? lots of people fit them on the wrong side and wonder why they get a soft pedal...... Quote Link to comment Share on other sites More sharing options...
Ian_Fearn Posted March 19, 2012 Author Share Posted March 19, 2012 Yep, bleed nipples at the top.... But thanks anyway! Quote Link to comment Share on other sites More sharing options...
GBMUD Posted March 19, 2012 Share Posted March 19, 2012 SEB500440 and SEB500450 Non-vented discs, they were in Britpart boxes but very clearly Lockheed parts (you can blatently see where all the lockheed and AP logo's are ground off) I have had cheap brake parts in the past (from another well known blue and white box supplier I think) with the OE makers name also cast into the part. Now call me cynical, but this appears to be from where the OE parts have been used to make the mould for the "Cheap Chinese Casting Company". In your case it sounds like the letters were badly ground off before the mould was made. I rather suspect that if Britpart could sell OE brake parts for £2.50 they would be shouting it from the rooftops, not grinding the name off to make it look like a cheaper part. Sorry to rain on your parade. The callipers you have bought may be just fine. Chris Quote Link to comment Share on other sites More sharing options...
Ian_Fearn Posted March 24, 2012 Author Share Posted March 24, 2012 Righto chaps, thanks for the replies on this. I bought a new master cylinder (Lucas one), fitted it and bled the brakes through. One of the rear bleed nipples gave up during bleeding so I bought 2 new rear calipers and fitted those too. I've re-bled the brakes countless times but the pedal travel is still way more than it used to be, my leg is well stretched out when i'm pushing it down. The real point for me is that the front pads are still loose in the calipers. I'd say theres between 0.5mm and 1mm on both sides. I can jiggle them around in the caliper. When the pedal is pushed down the pads are locked onto the disc and the pedal is hard, doesn't sink with time. What ever could be causing this??? I so need to get this sorted so I can use the car again. Cheers, Ian Quote Link to comment Share on other sites More sharing options...
Ian_Fearn Posted March 25, 2012 Author Share Posted March 25, 2012 I've finally sorted this. I went outside and 'exercised' the new calipers by taking the pads out and pressing the brake pedal. I then pushed the pistons back far enough to slot the pads back in and hey presto, its working perfectly now so I guess the moral of the story is that the calipers (both of them) needed some persuasion to get going. Cheers, (a very happy bunny) Ian Quote Link to comment Share on other sites More sharing options...
bushwhacker Posted March 27, 2012 Share Posted March 27, 2012 Glad to see you are now sorted. I was thinking it had to be air in the system before I seen your last post, but your sorted now so good stuff. Quote Link to comment Share on other sites More sharing options...
GBMUD Posted April 3, 2012 Share Posted April 3, 2012 What irony, I also have exactly the same symptom after replacing all four callipers this week. I will have to get them 'excercised' once the rain stops... During bleeding, and with this thread in mind, I was surprised how far the pistons retracted once the peddle was released. Perhaps I should have used more brake fluid during assembly? Chris Quote Link to comment Share on other sites More sharing options...
GBMUD Posted April 5, 2012 Share Posted April 5, 2012 Well, I tried exercising the callipers and it is much better. I now think that there may still be some air to get out... Chris Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted April 5, 2012 Share Posted April 5, 2012 Do you think that the exercising is basically lubing the seals up? Without the lube the seals are pulling the pistons back perhaps? Quote Link to comment Share on other sites More sharing options...
davie Posted April 5, 2012 Share Posted April 5, 2012 not wishing to teach anyone to suck eggs, but you do have the bleed nipples at the top don;t you...????? lots of people fit them on the wrong side and wonder why they get a soft pedal...... ooooohhhhh how easy that is to to - did rear discs, pads and calipers on my old disco once and couldnt figure out the problem. took 2 litres of fluid till i gave up and limped to garage, and yep on wrong side. never make that mistake again! Quote Link to comment Share on other sites More sharing options...
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