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Thread: Catastrophic brake failure like I have never seen before

  1. #1
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    Catastrophic brake failure like I have never seen before

    There I was on the way home this afternoon went to stop and the pedal went straight to the floor. No warning just zip, zero, zilch. Handbrake and gears brought her to rest without hitting anything. That was the excitement in my 1996 Defender 130.

    Had a quick look under the car and was easy to see fluid everywhere passenger front wheel. Was very close to home so crawled home very carefully.

    Whipped the wheel off and could not believe my eyes. The calliper was leaking from the join between the castings. Ok, but the 4 bolts that hold the two halves together were lose. I could turn them with my fingers! What the.?

    I replaced both front callipers in August last year at rego time new OEM. I remember reading the paperwork "never separate the haves of the calliper, ever"

    So anyone ever seen this kind of failure?
    I have replaced many callipers over the years and never ever even had a spanner or socket on those bolts before?
    There should not be a need to tighten them on new callipers?
    Certainly could not find a torque setting for them.

    Now what do I do? Take it back? Replace it? Just tighten it up?

    I will be checking the other side.

    Your advice welcome

    James

  2. #2
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    That is highly concerning if the parts were OEM and only 7 months old. I would not be touching this myself and I'd go straight back to the parts supplier for a complete replacement. Could have been a disaster if they'd let go when you really needed to stop on a dime. Following this with interest as I would really like to know the outcome.

  3. #3
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    Well I guess if a human assembled the caliper than mistakes happen.....brakes is about as bad as you can get with quality control.

    Maybe pull it off, clean it up and resemble??

  4. #4
    Roverlord off road spares is offline AT REST
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    That's highly concerning what Brand were these "O.E.M" Calipers?


  5. #5
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    Personally something like this would scare me so much I'd replace them with another brand all together, maybe even genuine.

  6. #6
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    Quote Originally Posted by zwitter View Post
    I replaced both front callipers in August last year at rego time new OEM. I remember reading the paperwork "never separate the haves of the calliper, ever"
    James
    I would be interested to know why the calipers can't be separated. I have overhauled hundreds of the things back in the late seventies and eighties.

    The overhaul kits used to even come with the seal to go between the two halves.
    Dave.

    I was asked " Is it ignorance or apathy?" I replied "I don't know and I don't care."


    1983 RR gone (wish I kept it)
    1996 TDI ES.
    2003 TD5 HSE
    1987 Isuzu County

  7. #7
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    The joys of being a pessimist is that I check and double check every visible bolt after a brake job, including the four through bolts. BTW there's nothing difficult about splitting calipers, done it quite a few times. Just make sure you have the correct seals at hand for reassembly.

  8. #8
    cuppabillytea's Avatar
    cuppabillytea is offline Loud Mouthed Rat Bag Gold Subscriber
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    Although you could just bolt it all up tight, you should take it back to the supplier if only to inform them of the problem. There should be a warrantee on them, so why do and pay for the work when they should?
    Cheers, Billy.
    Keeping it simple is complicated.

  9. #9
    JDNSW's Avatar
    JDNSW is offline RoverLord Silver Subscriber
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    My question is, since it has dual circuit brakes, why did this lead to total brake failure? This is exactly the sort of fault that having two braking circuits was supposed to save from leading to total brake failure.
    John

    JDNSW
    1986 110 County 3.9 diesel
    1970 2a 109 2.25 petrol

  10. #10
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    Quote Originally Posted by JDNSW View Post
    My question is, since it has dual circuit brakes, why did this lead to total brake failure? This is exactly the sort of fault that having two braking circuits was supposed to save from leading to total brake failure.
    I did wonder this myself when I read the OP.
    Dave.

    I was asked " Is it ignorance or apathy?" I replied "I don't know and I don't care."


    1983 RR gone (wish I kept it)
    1996 TDI ES.
    2003 TD5 HSE
    1987 Isuzu County

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