Little brake pedal travel left

Hi,
Im having trouble with my brakes and woundered if you guys could help me.

When i press my brake pedal with the engine running the pedal goes almost to the floor leaving about inch before it hits the floor. When the engine is not running the pedal feels ok (about the correct travel) but not fantastic. With both the engine off and running the pedal doesnt seem to creep. I have replaced many brake components now and still having no luck. Parts replaced : new lucas master cylinder, new brake pipes (not flexis), new brake pads, rebuilt rear calipers and put many litres of brake fluid through the system through bleeding (normal method and eazi bleed).

I have had this problem for a while now, and the parts i have replaced arent making any difference. They have been bled so many times before and after replacing parts and its costing me a fortune.

I Have also tried the vacuum pump test (holding brake on firmly then starting engine) and the pedal does go down to the floor much more, which when the landy is standing feels alot worse. Ive also pulled the vacuum pump hose of the servo and there feels a decent vacuum.

Another thing is, the back brakes dont seem to be working on the full width of the disk as they arent removing any surface rust off other than in the centre (hense why i rebuilt the rear calipers). Ive clamped the rear flexi hose and the pedal is far higher, but is this due to it blocking fluid being pushed??

Its a 300tdi 97 defender 90

If you could shed any light on this i would be really greatfull as im stumped with it to be honest. thanks, Josh.

If the pedal is good when you clamp the flexi pipe, then the problem lies with whatever is beyond the flexi. The calipers - you rebuilt them because they were only removing the rust from the middle, and not all over the disk..., and they're still doing the same thing after the rebuild?

When you press the pedal, and it goes to the last inch or so, what happens if you give it a couple of quick pumps? Does the pedal stop higher?

Thanks for the reply. Yes, the calipers are still only working on the middle after the rebuild. They are working but surely this isnt to their full potential.

The pedal still says the same when the pedal is pumped when the engine is on or off.

I'm not familiar with the caliper arrangement - do the mechancial bits all slide as they should? I was wondering for a moment whether it was something like the calipers being stuck, such that the pistons have too far to travel to work the pads properly, which might result in a long pedal and poor pressure on the disks.

That is what i though before i rebuilt them. I have replaced all the seals in calipers as well as the pistons. I have checked the pistons push out and return and they seem fine. I have also checked the rear flexi hose (when the engine is not running) and there doesnt seem to be any obvious signs of bulging and surely a flexi hose cant cause problems like this. Would the engine running highlight a problem with the flexi hose better??

I mean the mechanical fixing of the calipers to the ends of the axle, not the movement of the pistons. Are both sides of the disks getting the reduced rubbing from the pads? Running the engine will make it easier to get pressure thanks to the servo, but I don't know if it's necessary to have it running. As for the flexi, try clamping near the end towards the master cylinder, then at the other end, and see if there's any difference at the pedal.

:nospamhere:

Nomad Z said:

I mean the mechanical fixing of the calipers to the ends of the axle, not the movement of the pistons. Are both sides of the disks getting the reduced rubbing from the pads? Running the engine will make it easier to get pressure thanks to the servo, but I don't know if it's necessary to have it running. As for the flexi, try clamping near the end towards the master cylinder, then at the other end, and see if there's any difference at the pedal.

Click to expand...

They just bolt on with two bolts which i torqued correctly.

Yeah both of the rear disks on both sides are getting the reduced rubbing. I will try clamping the flexi at both ends and see what the outcome is..