Problem with Brakes, Discovery 2 TD5

[Si Click]

A brake pipe with rust on it should not fail a mot. An "excessively" corroded brake pipe will fail a mot.

True, but without any evidence you have no idea how close to excessively corroded the OP's vehicle is. This owner is clearly all over his brake system, but by the time most owners notice their pipes are rusty, they are probably already fairly terminal. If he is unsure himself if the rust is an issue, surely the best advice is not to ignore them and concentrate on the rest of the system, but to have them assessed by someone experienced enough to tell if they are excessively corroded or not.

 

[EeEk]

This owner is clearly all over his brake system

Does that translate into the owner doesnt have a ****ing clue....thats why hes here asking some other copy n pasters for an answer to something that 3 workshops say doesnt exist. As for binding....where...when? Its been road tested and all brakes are the same temp....??? wheres the binding?

Once a second hand modulator is fitted and all the brake pipes are changed, it'll be fixed ...assuming the second hand modulator is perfect

 

[Marcolandy]

And also, once replaced you won't need to do it again for ages.
Can't mess about with brakes.

Dear Stanleysteamer,
I know, I don't want to risk anything, as I drive 35'000 km a year with my Disco 2.
The last garage checked the rust, as the replaced the flexis, and the told me, there is rust on the outside, but not inside. They did also a pressure test, and everything was fine.
But for sure, long term I will change them.
Thanks for the advise.

 

[Marcolandy]

Marco, sorry to bring bad news, but if the solid brake lines are rusty then they should be replaced. I don't think that internal rust would be likely, but the potential for the external rust to weaken the pipe enough for the internal pressure to force a rupture leading to a catastrophic brake failure, is significant. In the UK rust on brake pipes would almost certainly cause the vehicle to fail it's annual MOT (UK roadworthiness test).

Dear Si Click,
thanks for your message.
I know that is a bit risk and I have to take it serious. The garage you change the flexies told me, that the is a bit rust, but the pressure is still perfect. But also they told me, that I should consider to change the solid brake lines by end of 2021. I passed the inspection last year, but I will replace the pipes before the next inspection, otherwise the vehicle would fail the MOT.
Appreciate your concern and your help. Thanks a lot.

 

[Marcolandy]

+1^

If you have the relatively simple gear to make them up, you can make your own out of Kunifer, and they won't rust.
https://www.google.com/search?q=kun...0l3j0i395l3.2159j1j7&sourceid=chrome&ie=UTF-8
A brake pipe flaring tool for copper doesn't have to be as strong.
Us in the kit car game make them up all the time.
Or elses you get pros to make them up or you buy a set.
That's about it really.

Altho it may be possible to just replace the rusty bits by cutting and inserting new steel pipe.
But if you do that agin you'll need to make the flared ends.

Thanks for the link.
As is essential feature regarding security, I don't dare to do it myself. But I will send the garage the link for the kunfier brake pipe.
Thanks for all your help. Really helpfull, appreciate that a lot.

 

[Marcolandy]

Mine had a similar issue last year... Front left and rear right calipers stuck on. Luckily I was only 1/4 mile away from home, so I loosened off the pipes to these from the master cylinder and limped home. One hand on the handbrake. Replaced the master cylinder, and that fixed it. I did notice you had already done this though...

Lucky you.

 

[Marcolandy]

I know

I just think its amusing that and were now at the brake pipes rusting on the inside....FFs the chassis of a disco will be long gone before the brake pipes rust from the inside.

The list at the beginning doesn't mention discs....so new pads on old discs and everything is supposed to sit perfectly. Start with the obvious

Dear Ee Ek,
thanks for your inputs. Appreciate that.
True, I forgot to mention the discs. Sorry for that. All 4 discs were replaced as well.

 

[Marcolandy]

I tend to agree with you and I do think that there is no direct evidence yet that the ABS mod is suspect. If I were the OP, I would connect the master cylinder directly to the brake lines leading to the binding calipers (one on the primary port & one the secondary port) and see what happens. You can either use the old flexi pipes to bridge between pipes or simply connect the corresponding brake tubes on the ABS mod with female to female adapters.

Note : Do not carry out road tests with this configuration. Only applicable for garage testing.

Dear NPG,
Thanks for the suggestion.
sounds good, the narrow it down. Let you know the result once done.
Thanks

 

[Marcolandy]

True, but without any evidence you have no idea how close to excessively corroded the OP's vehicle is. This owner is clearly all over his brake system, but by the time most owners notice their pipes are rusty, they are probably already fairly terminal. If he is unsure himself if the rust is an issue, surely the best advice is not to ignore them and concentrate on the rest of the system, but to have them assessed by someone experienced enough to tell if they are excessively corroded or not.

Dear Si Click,
true, and I already let it checked: they are not excessively corroded. A bit rust here and there, but I already decided to let change the brake lines by the end of this years, 2021.
Thanks for your input

 

[Marcolandy]

Does that translate into the owner doesnt have a ****ing clue....thats why hes here asking some other copy n pasters for an answer to something that 3 workshops say doesnt exist. As for binding....where...when? Its been road tested and all brakes are the same temp....??? wheres the binding?

Once a second hand modulator is fitted and all the brake pipes are changed, it'll be fixed ...assuming the second hand modulator is perfect

Dear Ee Ek,
looks like you did the sum up of all the inputs and make a plan: thanks for that.
This will be done; first I let changed the ABS Modulator with a second hand one. Hope there is an effect on the permanent touching pads. If not, then the brakes lines will be change immediately.
Thanks again for your support.

 

[Marcolandy]

To all of you:
I got so valuable information and technical support from all of you, that I know not, what to do.
It will take some time, but as soon as I have some results, I will come back end explain what has been done, and what was the final solution.
So that anyone with the same problem find probably the solution here.

meanwhile; thanks all of you for your time and help. Appreciate that very much. I do not take that for granted, that you donate so much of your time and generously sharing your knowledge. THANKS A LOT!

 

[Stanleysteamer]

Thanks for the link.
As is essential feature regarding security, I don't dare to do it myself. But I will send the garage the link for the kunfier brake pipe.
Thanks for all your help. Really helpfull, appreciate that a lot.

You'll scare them sh!tless! they won't be used to doing anything other than buying in sets of brake pipes ready made up and fitting them.
they may not even have the gear to make the flared ends!
If I was you, i'd get the modulator sorted out first before replacing rusty pipes, unless they are so rusty that brake fluid is actually leaking out of them.
One thing at a time, i.e. sort out the initial problem first.

 

[Marcolandy]

You'll scare them sh!tless! they won't be used to doing anything other than buying in sets of brake pipes ready made up and fitting them.
they may not even have the gear to make the flared ends!
If I was you, i'd get the modulator sorted out first before replacing rusty pipes, unless they are so rusty that brake fluid is actually leaking out of them.
One thing at a time, i.e. sort out the initial problem first.

It's a while ago since we last spoke.
What happened: I got a modulator and replace the old one. Where there any changes? Unfortunately the brake problem wasn't solved. There were no changes.
Conclusion: I have to replace the rusty brake lines. :-(
I will come back with an update, when it's done.

thanks for helping me to narrow it down to find the reason for the binding brake pads. I'm very grateful for your support and for the support of all you guys in this forum: thanks a lot!!!