Thread: changing brake rotors on 300tdi defender

sorry no pics.......

tools that i accumulated from start to finish

jack stand
bottle jack
wheel brace
rachet
beaker bar
1/2 socket (claiper bolts)
13mm ring/open ender (calliper bolts)
13mm ratchet ring spanner (calliper bolts)
15mm socket with small extension (rotor bolts)
16mm socket (drive flange)
large flat tip
small flat tip
hub nut socket
15mm open ender (front brake line bracket)
16mm open ender (fron brake line bracket)
loctite
grease
14v snap on rattle gun
brake line spanner.......cannot remember the size
large shifter (maxi drive nuts)
2 x multi grips (brake lines)
circlip pliers
sledge hammer
2 x smaller hammers
bronze drift
solid punch
gasket sealant
rags, plenty of rags
will check my pile tommorrow, i might have forgotten something

parts
4 x rotors
4 x hub seals'
4 x gaskets
4 x lock washers
front and rear brake pads

some points of interest

• could not remove either of the rear brake lines so after rounding the first and after spraying the second it also ended up rounded i cut the lines. the drivers side has had a rough time by the looks of it as it was bent all over the place
• no oil was found in either of the two rear hubs, both have been converted to oil lube, good thing i fully greased the bearings when i fitted the maxi axles
• one rear and one front rotor need a sledge hammer to seperate them from the hub
• all bearing looked in perfect nick, 7-8 years 150 000 km at a guess
• replaced six of the bearings as i had them, 7th bearing was incorrect size and the 8th was issing the cone
• front left could have done with a speedi sleeve, wonder if this will bite me later
• rear maxi drive axle and flanges had zero wear approx. 150 000km old, i was hoping the passenger would have loosened up as i had to belt them together when i fitted them..........had no choice as it was the night before leaving for our simpson desert trip
• front standard drive flanges and axle had zero wear, km unknown.....think lots
• front bearings are greased, not oil, left them that way as the bearing were perfect plus no oil makes it into the rears
• took me around 11 hours, included was a trip to supa cheap to purchase a set of circlip pliers, a shower before lunch, morning tea with the kids
• the uneven wearing of the pads were not as bad as i thought......left the callipers and will monitor every 5 000 km
• two drivers side rotors destroyed
• rear left rotor was 11.7mm,min is 13mm? from memory
• front left rotor was 1mm over min.
• front right calliper has me concerned as it was super hard to push the inside pistons back, will monitor
• driveside pads had heap of meat, maybe half worn
• passenger side pads were down to metal
• shock rubbers were all in good nick
• trailing arm bushes need replacing
• found some rust where the out of normal mounting of mud flaps are
• still have one stripped drive flange bolt on the front hub.......its been this way for at least eight years so no need to worry
• tie rod end all good
• really need to fix up front bar, its ****ting me
• cordless rattle gun for dis-assmebly was handy although i am carful and used a ratchet for bolts that didn't spin freely, sometimeyou just need to feel whats happening
• two sets of protective clothing.........it can get a little messy working around me......plus work has changed names so these will go straight into the bin

just need two brake lines tomorrow and we should be able to bleed the brakes and be back on the road

$500 in parts form local supplier
i guess i saved a few dollars in labour

best bit is i have a good understanding of the condition of the brakes and hubs

pretty happy with the goings on

Picked up my new brake lines yesterday, off the shelf ready made ones are expensive, only the long was available at $160. M R made them up on the spot using two of the fittings and supplied the other two for a grand total of $32.

It took I bit of time bending the new lines into shape.....considering silly me left the old ones with M R.......

I was having all sorts of trouble bleeding the rear left so went and did the other three......ended up pulling the bleed nipple out to fine it full of mud grrrrr

Test drive tells me everything is running just fine, glad to have brakes back