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taazzukcb



Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

United Kingdom 2004 Defender 110 Td5 DCPU Stornoway Grey
Brakes Aren't Strong Enough
Hi All,

I have a couple questions I keep meaning to ask.

I have a 110 TD5 DC which last weekend I gave a complete brake overhaul. It's had all 4 new callipers (OEM AP), all 4 new discs (OEM Delphi Lockheed) and 4 sets of new pads (again, OEM Delphi Lockheed).

I did this due to the originals being in an interesting condition and the fact the rear were seized to hell and fronts, though working, didn't look in great nick either. Bad rusting. I also couldn't get them to lock! I know locking isn't good in an emergency situation, but I still believe that even a 110 DC should be able to lock-up all 4 wheels.

Having done all this work, they still will not lock. I can boot the brakes to only get a reasonably hard, but only reasonably hard braking force. I can push until the M/C wont give any more, but still no locking up. Is this right? My 90 can lock up very easily if I wanted and the brakes just feel so much better even though the Callipers are original!

I also bleed thoroughly and put a couple litre of fresh fluid through to clear th lines through.

Anyone got any advice on this?

Next up is the steering box. I am converting to a disco drop arm and have the daunting task of removing the drop arm. I also have a spare steering box in the shed which although used, was a reasonably fresh refurb and still look pretty smart. When I turn the shaft splines with my fingers (very tough), the drop arm splines turn, but feel very notchy, is this correct of an empty box? I dont think there's to much wrong with mine, but I dont know, so I'm wondering if there's a way to test my spare box so I can set that up with the disco arm and just swap the boxes and again, gives me a reason to refresh the fluid to!

What should the box feel like when off and disconnected?

Kind regards to all!


Last edited by taazzukcb on 9th Jun 2014 11:02am. Edited 1 time in total
Post #336063 5th Jun 2014 9:27pm
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roel



Member Since: 08 Aug 2009
Location: Lelystad
Posts: 2039

Netherlands 2003 Defender 90 Td5 PU Caledonian Blue
I have little experience with 110's but I think you should be able to fully lock-up all wheels. (You don't have ABS I assume).
I just did my Defensive driving course and there they say you need to be able to push 70 kg on the brake paddle. In my normal seating position I could not. Whistle My leg was stretched before I came close to 70 kg.

New brake pads do not have the full grip yet but I think you might have a problem with your brake servo.


I don't have any answer on your steering question. Roel

1984 90 2.5 na Diesel - RR V8 (1994-2001)
1997 Camel Trophy Discovery 300TDI (2001-2009)
2005 G4 Discovery III 4.4 V8 (2008-2018) It's gone but it still hurts.
2003 90 Td5 (2009-now)
Post #336111 6th Jun 2014 6:47am
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taazzukcb



Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

United Kingdom 2004 Defender 110 Td5 DCPU Stornoway Grey
Hi Roel,

Nope, no ABS on this one. Pretty sure I'm putting well over 70kg into the peddle, nut still nothing. I did wonder about the servo!

I'd expect they should be fully worn in after 200 miles, so I hope they are at their optimum bite. They've had the maximum available surface area being new pads on new discs so should of worn in within the first 100 hopefully. I'll keep running them in for a little longer though to be sure.

Are there any tests I can perform with the servo to see if it's shot? I can build up pressure with the engine off, then when I rest my foot on pedal I can feel it go down when I turn the engine on, so it's trying to 'assist'. Just doesn't have the grunt to lock completely!
Post #336120 6th Jun 2014 7:50am
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taazzukcb



Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

United Kingdom 2004 Defender 110 Td5 DCPU Stornoway Grey
Update: Drove a friends, new to him, Disco 2 TD5 back to his house on Saturday just gone and the brake were original but on a whole other planet! Bloody hell could that thing brake! I'm even more sure there's something wrong with mine.

If anyone can help it would be appreciated!
Post #336849 9th Jun 2014 11:01am
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Clive



Member Since: 21 Mar 2014
Location: Littleborough
Posts: 467

United Kingdom 2004 Defender 90 Td5 X-Tech LE Zambezi Silver
Might be worth checking the vacuum pump and lines, could be a leak or a faulty pump preventing full servo assistance.
Post #336852 9th Jun 2014 11:08am
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BigRuss



Member Since: 15 May 2010
Location: Norfolk
Posts: 2785

United Kingdom 2010 Defender 110 Puma 2.4 USW Santorini Black
Are you bleeding the brakes in the right sequence? If not you could in advert ably be putting air in the system. Russell
2011MY 110 XS USW Black
Post #336855 9th Jun 2014 11:17am
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taazzukcb



Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

United Kingdom 2004 Defender 110 Td5 DCPU Stornoway Grey
Bleeding goes from furthest to closest. That's how I've done cars so assume this is still correct? When changing the callipers I used a pipe bung when removing the old, then placed the lines into the new callipers. So in theory there should of only been air in the callipers and did each one, one by one. And bled each one after putting it on!

I will give it another bleed, but I'm almost certain they're pretty much air free!

I have though about the vacuum pump. Could the M/C also be an issue, or if these go, do they usually leak etc? As mines leak free (M/C is anyway :p).
Post #336868 9th Jun 2014 12:06pm
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rallysteve



Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2229

United Kingdom 2002 Defender 110 Td5 DCPU Keswick Green
The pads will need to bed it before the braking performance will be optimal. As a side not fitting new discs and pads then immediately attempting multiple emergency stops will not help the discs or pads!

I trust you fully degreased the discs before fitting them?

Our 110 DC wothout abs can easily lock all four wheels on dry tarmac with goodyear wranglers.

Cheers
Steve 02' 110 TD5 Double Cab Rebuild Thread
Post #336878 9th Jun 2014 12:26pm
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taazzukcb



Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

United Kingdom 2004 Defender 110 Td5 DCPU Stornoway Grey
Hi Steve,

Sorry, I should of added. First 100 miles we're bedded in properly, then the next 250 miles were reasonably normal with a few heavy braking instances, but by 350-450 miles, I would of normally expected bedding in to be done! And yep, fully degreased!

Cheers.
Post #336880 9th Jun 2014 12:29pm
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rallysteve



Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2229

United Kingdom 2002 Defender 110 Td5 DCPU Keswick Green
Thats okay then Very Happy

Often come across people who seem to think that fitting new pads and discs then braking as hard as they can from 1000mph will bed them in!

How does the pedal feel when the engine is switched off and the servo vacuum has gone (pump pedal a few times after turning off)?

Steve 02' 110 TD5 Double Cab Rebuild Thread
Post #336883 9th Jun 2014 12:35pm
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g-mack



Member Since: 07 Jan 2014
Location: northumberland
Posts: 1967

United Kingdom 
servo test i did.
run engine, spray servo around the nuts that hold brake cylinder to it (front of servo)
get it nice and wet, switch of engine
listen for hissing!!!! My 109 thread

my youtube channel
Post #336886 9th Jun 2014 12:40pm
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taazzukcb



Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

United Kingdom 2004 Defender 110 Td5 DCPU Stornoway Grey
I've seen someone do that on a tin top racer, resulted in a blown disc and very badly damaged four figure wheel! So I tend not to do that to much!

Just gone and sat in the car park flashing away with the brake lights :p! On instant getting in, pedal moves a little then stiffens up as you'd expect, after 6-10 pumps, still feels the same. Start engine with foot rested on pedal, I'd expect movement and could of sworn blind it used to, but there was no movement, btu after a let off and repress it went a little further. Then turned engine off and after 6-10 more pumps, again, very little change. Bit of movement, then rock solid! But like I say, on the road, this doesn't result in to much brake power.

Hope you get my description anyway, not the easiest thing to try and write down :p!
Post #336887 9th Jun 2014 12:43pm
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rallysteve



Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2229

United Kingdom 2002 Defender 110 Td5 DCPU Keswick Green
Possibly sounding like a servo problem then! If its a TD5 im guessing that you have the EGR vacuum solenoids on the offside inner wing. Check all of the pipework around them to make sure that you are not loosing vacuum through them. Also check the main vacuum pipe leading to the servo.

Steve 02' 110 TD5 Double Cab Rebuild Thread
Post #336894 9th Jun 2014 12:50pm
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diesel_jim



Member Since: 13 Oct 2008
Location: hiding
Posts: 6093

United Kingdom 2006 Defender 110 Td5 SW Epsom Green
I had a similar problem with my 110. the brakes were never very good. good enough to pass an MoT, but like you say, wouldn't lock up.

When I built my project90, the brakes ont that were great (and they were 110's all round, i.e. larger rear dics and calipers) so i'd expect it to brake a little better anyway, but it was night and day compared to the 110.

Anyway, one day I decided to swap parts over and eliminate the problem (I'd bled the 110 brakes about 3 times with a gunsone easybleader so knew it was AOK air wise)

Turned out to be a 2 pence O ring between the back of the pedal and the servo. I had the bonnet removed, and had turned the engine off, got out and heard a "Pssssst" noise... air leaking.

It was this O ring. and it was letting vacuum out. so eventhough there was some vacuum, there wasn't enough.
Changed the seal. bam! instant better brakes.
Post #337207 10th Jun 2014 12:21pm
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taazzukcb



Member Since: 30 Aug 2013
Location: Derbyshire
Posts: 663

United Kingdom 2004 Defender 110 Td5 DCPU Stornoway Grey
Hi All,

Just thought I'd update this ...

I've been messing around with steering lately so the brake took aback burner but yesterday whilst outside a friend I decided to pull the vacuum hose.

Started engine, pulled fitting off of the Servo and put me thumb over. Damn thing nearly pulled my thumb in! There's a reasonable amount of suction there!

At the weekend I had the engine cover off for the first time and found the EGR vacuum pipes were left un-blanked and still plugged in (this is what brought the brakes back to my attention).

To a certain extent, I thought great, might be an easy fix this! Plugged the vacuum hoses and also unplugged the solenoids for good measure so it wouldn't even activate them anyway. Went for the test drive after the steering malarky, but nope ... braes still the same!

Every now and again though since this, sometimes I get a lot more movement on the pedal, usually the first push after the trucks been sat, but second or third pump, it's back to stiff with what feels like no assistance!

Brakes will be well and truly bedded in by now and I've bled again with no air.

Is this a Servo problem now if I'm getting plenty of suction!? (Ooer!) Or could the M/C still be at fault?

On a side note ... the ROW Brake vacuum pipe that doesn't have the 'T' Piece (no EGR) in used to be like £12-13 ... Only 2 places that have it want over £100 for the hose! Utterly appalling!
Post #340444 24th Jun 2014 11:20am
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