Oh bugger, help needed...

Also noticed last night that it had an extra thrust washer stuffed under the top pin, explains why its got a great thick wedge of shims under the pin i suppose

Ok, parts arrived.

The caliper / disc upgrade is the first stumbling point...

The calipers each have TWO pipe fittings but i only have ONE pipe, what do i stuff in the other hole?

Need to get parts today from somewhere.....

i've just got a new set of disco one rear calipers and mine came with a blanking bolt in the second hole ,i presume it's to be compatible with more than one model,

Turns out that ABS ones had one pipe, non ABS had two pipes, cant find anyone that will talk to me regarding the upgrade as its cross-model etc and wont talk in case its wrong

Where am i going to find a blanking plug now????

One dealer even said i cant blank it as one pipe does one side and other one does t'other.

get a brake pipe connecter and weld a spot in the hole to create a blank or maybe a bleed nipple will fit ,my axle is off a 1992 200tdi disco and i intend to fit it to my 90 soon which only has the one on the old drum circuit ,i'll just nip and see if the bleed nipple fits the blank hole gimme a minute.

nope the bleed nipple don't fit and it ain't the same size as the brake hose connecter so don't know mate.

Ok, dashed up the local car spares emporium and got two T-Pieces with the same threads so i can go from my flexi to the T then from the T to each fitting on the caliper.

The bleed nipples do fit the same thread on these calipers so after spending my £££ i realised that i could also have run a pipe from a spare bleed nipple fitting to the other connection, each caliper has three nipples!

Hope that sorts it out.

davek0974 said:

Ok, dashed up the local car spares emporium and got two T-Pieces with the same threads so i can go from my flexi to the T then from the T to each fitting on the caliper.

The bleed nipples do fit the same thread on these calipers so after spending my £££ i realised that i could also have run a pipe from a spare bleed nipple fitting to the other connection, each caliper has three nipples!

Hope that sorts it out.

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they must be different to mine then mate ,never mind worth a try.

200tdi calipers have three nipples and two pipe fittings, 300 tdi calipers have one nipple and one pipe.

The twin pipes on the early calipers is because each pipe is on a different circuit. The idea is that even if one circuit fails, you still have braking at both front calipers.

Bear in mind you need to bleed two nipples at once, and then the last one on its own. I can't remember which ones exactly but it's in Haynes.

Tbh mate I'd be looking to get 300tdi calipers for my 300tdi!

The early calipers were AP Racing, the later calipers are Lockheed I think. Either way you might not have success with a single circuit feeding a twin circuit caliper, especially when trying to bleed.

Save the hassle and get the right ones in my opinion.

Cheers.

The info I have is that disco 1's without ABS had dual circuit calipers, with ABS they had single circuit calipers BUT they also say that ABS models never had vented discs which I want to fit.

I can't see any problem with the job as long as all fits physically, bleeding can be dealt with later and from an operational POV split circuit calipers will need exactly the pressure and flow as a single circuit one as pots are same size etc so should work ok.

The big question is , will it fit?

In the surprising amount of boxes that arrived was the swivel kits, these contain oil seals but naturally the bags are not labelled and a couple look almost the same? There are three odd seals, odd in that they all have steel between the inner and outer edges and not just rubber coated steel as most lip seals do.

The parts list shows FTC3276 halfshaft oil seal and FTC5268 inner stub axle seal. I can see where these go but where do the others fit or is it some kind of universal kit???

When reassembling stuff i normally pack bearings with grease, book says oil in this instance, but it uses one-shot which is a bit of both really.

Pack swivel bearings with grease then reassemble??

I take the top bush (abs type) is greased too as one was pretty dry when i took it down, possibly why it was worn.

When I got my swivel kits there was a little rubber/steel item in there, one in each kit in its own black plastic bag (Britpart) and I couldn't work out what it was. I didn't take anything like it out of the original axle so I guessed it must be surplus, because my kits came with both the 8 and 12 mm swivel ball seals, so I guessed it was either some kind of seal or bush for a later model.

Just replace what you've already got I guess.

Cheers.

Yeah, I've matched and replaced what came out, all seems to fit right. Also got the preload set and both hubs partially reassembled ready to go back tomorrow, gave it all a nice coat of gloss black paint, looks sweet

When flaring brake pipes, what's the rule for double or single flares??

is allways a good idea to pack bearings with grease ,with brake pipes single flares are never used ,male union has a first operation flare which is a convex cone ,female has second operation which is concave

jamesmartin said:

is allways a good idea to pack bearings with grease ,with brake pipes single flares are never used ,male union has a first operation flare which is a convex cone ,female has second operation which is concave

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That's what I thought and have done, thanks for the tip re the flaring.

Hopefully the weather will stay clear and I can get the old girl off the axle stands today

All done, after some headaches with parts sent in error and a leak or two

Hopefully be leak free for a good few miles now.

Thanks to all who offered advice.

Looking good, I'll be attempting next week. In general though found it ok?

If you think Landy brakes etc. are bad, try them on Effin trucks wi' air operated disc brakes, bloody back-breaking nightmare.

jamesie said:

If you think Landy brakes etc. are bad, try them on Effin trucks wi' air operated disc brakes, bloody back-breaking nightmare.

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Aye and usually siezed