Hi all, thought I would share my experience bleeding the brakes on the Defender.
Background - complete new system fitted (except hard lines) Braided flex lines. calipers, master cylinder, booster and rotors.
Quality items fitted.
I'm not new to bleeding brakes but the Defender has been the most troublesome I've come across to date.
I was expecting the bleeding to take longer than normal and had read and heard of frustrations with the system bleeding, but wasn't expecting it to be this tedious.
Bleeding with engine off was typical and gave a firm pedal - cycled around 1 and half reservoir of fluid.
When the engine started pedal went to the floor.
Bleed again with engine running finally gave a satisfactory pedal (about half a reservoir used) but after around 3 seconds the pedal would slowly sink to the floor.
After much more bleeding (3 reservoirs) and an unhappy assistant, I couldn't get a firm pedal to hold more than a few seconds before slowly sinking to the floor.
I decided the new master cylinder was a dud as the brakes were displaying classic internal MC failure behavior and I wasn't/couldn't get any air from the system.
Another new master cylinder fitted and same problem.

I couldn't have 2 dud MC so contemplated the inability to get a firm pedal.
My thoughts are the design in these dual piston calipers must have a hard time clearing air under what most would consider typical bleeding techniques and must be the problem. Some persistent aggressive bleeding was required.
Not having an assistant around caused me to lash out on a vacuum bleeder from Supercheap.
Using the bleeder is very easy, though has some behavior which needs to be understood.
The nature of a bleed nipple will cause air to be drawn in around the nipple thread whilst drawing fluid at the same time when under vacuum.
This makes it very hard to determine if the air seen in the tube is from the system or drawn externally.
This is where the vacuum gauge needs to be utilised for more than an initial hg value.
Watching the gauge pressure reduce, you can see the rate of vacuum reduction flicker/drop rapidly and then stabilise.
This is the indication of air being drawn from the system.
When the gauge consistently falls at a steady rate with no flickering the system should be free of air.
now..
I say "should" be free of air because the Defender was still playing shennanigans. The pedal was better but not good.
I applied nearly 3 times the vacuum suggested and cracked the nipple wide open and found this is what was needed to get the last air out.
Now I have a great pedal and added a very helpful tool to the kit.
Plus a new master cylinder now for sale.
The vacuum bleeder also comes with multiple adapters so you can test vac systems, valves, manifolds etc.
Some of you may already know this but hopefully it may help some others.
Bookmarks