DISCO 2 2000 TD5 BRAKE FAULT

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J

JD HOGG

New Member
Posts
7
Location
GLOUCESTER UK
Hi
Hope somebody can help me.
I've replaced all four discs, pads, calipers & brake hoses.
Brakes have first been bled manually.
Then bled using Delphi through ABS pump.
No air at any point, No leaks.
Brake pedal still goes to the floor, but will get a pedal if pumped up.
I'm suspecting the master cylinder!!!!!
The brake pedal was a problem (previous to changing brake components) after I had to stand on the brake pedal hard to avoid a vehicle that pulled out in front of me, But wasn't spongy all the time like now.
 
JD HOGG said:
Hi
Hope somebody can help me.
I've replaced all four discs, pads, calipers & brake hoses.
Brakes have first been bled manually.
Then bled using Delphi through ABS pump.
No air at any point, No leaks.
Brake pedal still goes to the floor, but will get a pedal if pumped up.
I'm suspecting the master cylinder!!!!!
The brake pedal was a problem (previous to changing brake components) after I had to stand on the brake pedal hard to avoid a vehicle that pulled out in front of me, But wasn't spongy all the time like now.
Click to expand...

If by “bled manually” means pushing the pedal down to the floor each time, then it could well be now down to an iffy master cylinder seal caused by the piston travelling into unknown territory, therefore that unused part of the piston which is corroded has ruined the seals, something old vehicles can suffer with.
I was there with this issue years ago when changing fluid with another vehicle I own, now I use an ‘ezzlbleed kit’ but with the disco I only press the pedal half way and use a one man bleeding kit which is a simple bit of tube and a inline one way valve which works, the ezzibleed kit supplied cap doesn’t have a tight fit for my disco so don’t use ezzibleed.
 
Hi, after you replace the master cylinder do the power bleed first as the air from the modulator to get into the brake lines before you pedal bleed it cos the other way around is inneficient as while you pushed out the air from the lines with pedal you put air in them again under the modulator so all the fluid from the lines must go out again as to bleed the air out if you see what i mean... and respect the sequence from the shorter to the longest line
 
sierrafery said:
Hi, after you replace the master cylinder do the power bleed first as the air from the modulator to get into the brake lines before you pedal bleed it cos the other way around is inneficient as while you pushed out the air from the lines with pedal you put air in them again under the modulator so all the fluid from the lines must go out again as to bleed the air out if you see what i mean... and respect the sequence from the shorter to the longest line
Click to expand...
Thank you for that
I think it’s the modulator valve that Delphi tells me to do 5 times in a row first.
Must be the advice you have given me.
Thank you.
You have to hold brake pedal down and hold down until it says release pedal.
Be prepared for the brake pedal to push back and vibrate Quite a bit.
I’ll repost if the new master cylinder actually turns up Friday.
 
YAY it finally turned up.
Fitted it to disco.
Bled all brakes.
They are better but not perfect.
Then on a whim.
Looked at front calipers to notice the bleed nipples are at the bottom, that’s the way the original ones were fitted.
Decided to swap them over so nipples are now at the top.
Bled brakes again and perfect 1st time.
So note to all
The bleed nipples need to be at the top regardless what the old ones were like,
Lesson learned
Hope this will help others with similar problems
 
JD HOGG said:
YAY it finally turned up.
Fitted it to disco.
Bled all brakes.
They are better but not perfect.
Then on a whim.
Looked at front calipers to notice the bleed nipples are at the bottom, that’s the way the original ones were fitted.
Decided to swap them over so nipples are now at the top.
Bled brakes again and perfect 1st time.
So note to all
The bleed nipples need to be at the top regardless what the old ones were like,
Lesson learned
Hope this will help others with similar problems
Click to expand...
Cannot imagine how anyone ever thought you could bleed the brakes with the nipples at the bottom.:confused::confused::confused::confused::confused:. air floats to the top of a liquid.;););)
Good call!!!!!:):):):):)
 
You do have to wonder at the mental illness afflicting the person who fitted the callipers upside down and therefore presumably on the wrong wheels.
reminds me of old style minis where the Brake piston often had the brake pipe in the top port and the bleed nipple in the bottom one.
Bonkers!!!
 
Last edited:
skintnow said:
Had the Joy's of front ball joints on Tuesday followed swiftly by seized front calipers on Friday all that's left now are rear anti roll bar links and she is ready for retest
Click to expand...
If you can do those feck off tough ball joints on your own, you don't need our help much!!!:):):):):)
 
skintnow said:
He is Rumanian and strong as an ox.
I could not move the press any more but he Gently pushed me to one side and pulled on the bar like it was not attached to anything .The Joy's of youth
Click to expand...
He being....? Neighbour? Mate?
Sounds like every home should have one!!!
 
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