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rich_allen

Member Since: 10 Jun 2016
Location: Rutland
Posts: 21

Brakes! Or lack of….

Evening all… hoping I can rack someone’s brain or there are some brake gurus out there..

This one has me stumped!

2002 Defender 90 TD5..

The brakes have been pretty rubbish for quite a long time but now seem to have completely given up..
My pedal goes straight to the floor with almost no braking force applied. It does not matter if the engine is running or not, or if it’s moving or not…. It’s the same in all conditions.
It has larger 110 rear calipers, LOF 6 pots on the front. Braided lines all round, I’ve replaced the master cylinder twice (to rule out the first one being faulty - both genuine TRW)
Ive just replaced the bias valve today and rebled about 6 times and still the same…
I fitted the LOF brake booster kit to see if that made a difference but no… put the original booster back on today just incase and still the same…..
No fluid is being lost, no visable leaks…

HELP!! 😂

It’s the most basic of systems but I can’t get a pedal!!

Cheers

19th Jul 2025 9:16pm

miker

Member Since: 13 Sep 2015
Location: Surrey
Posts: 1784

Is there a difference between 90 and 110 master cylinders normally?

It kind of sounds like you may have a lot more slave cylinder capacity (bigger 100 calipers and 6 pot fronts) but no more fluid being pushed to them....

Just a theory mind you.

19th Jul 2025 10:13pm

landy andy

Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5978

2006 Defender 110 Td5 USW Zermatt Silver

Can you manually bleed them?

Are you able to get fluid out of bleed?

What does pedal feel like, any resistance?

Have you adjusted the brake actuator rod?

Are your wheel bearings all spot on?

Last edited by landy andy on 20th Jul 2025 6:19am. Edited 2 times in total

20th Jul 2025 2:36am

jim4244

Member Since: 13 Apr 2014
Location: Bedfordshire
Posts: 971

2013 Defender 90 Puma 2.2 CSW Fuji White

Hi

Have you checked the seals in the slave cylinder?

Jim

20th Jul 2025 4:25am

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8324

2011 Defender 110 Puma 2.4 USW Stornoway Grey

Insufficient travel in master cylinder. Increase pedal stroke. Will need to displace fair amount of fluid to push all pistons in.

How are you bleeding it? Pressure kit? Cheers

James
110 2010 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

20th Jul 2025 7:30am

rich_allen

Member Since: 10 Jun 2016
Location: Rutland
Posts: 21

miker wrote:
Is there a difference between 90 and 110 master cylinders normally?

It kind of sounds like you may have a lot more slave cylinder capacity (bigger 100 calipers and 6 pot fronts) but no more fluid being pushed to them....

Just a theory mind you.

I did wonder this but even if this was the case surely I’d have some sort of pedal?

20th Jul 2025 12:57pm

rich_allen

Member Since: 10 Jun 2016
Location: Rutland
Posts: 21

landy andy wrote:
Can you manually bleed them?

Are you able to get fluid out of bleed?

What does pedal feel like, any resistance?

Have you adjusted the brake actuator rod?

Are your wheel bearings all spot on?

Been using a pressure bleeder, fluid comes out the nipples lovely, just as you’d expect. I’ve probably flushed 2-3 litres through…
Very little resistance on the pedal… a little but not a lot. Bearings all feel nice and tight.
Haven’t touched the brake actuator rod, (what would I need to do to that, does that make a huge difference?)

Cheers

20th Jul 2025 1:00pm

rich_allen

Member Since: 10 Jun 2016
Location: Rutland
Posts: 21

jst wrote:
Insufficient travel in master cylinder. Increase pedal stroke. Will need to displace fair amount of fluid to push all pistons in.

How are you bleeding it? Pressure kit?

Yes, pressure kit, even with the amount of fluid needing to be pushed I would have thought id have some pedal.. I’m sure there are plenty out there with bigger brakes and normal master cylinder?

20th Jul 2025 1:02pm

landy andy

Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5978

If you manually bleed them, can you get a good squirt of fluid out?

That is what I would be trying for

20th Jul 2025 7:19pm

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8324

I have uprated front 6 pot calipers. I would be checking your getting sufficient stroke from the mc to displace enough fluid.

But yes you should have something from any press.

Try the manual bleed option.

Calipers right way up? Nipple at top? Cheers

James
110 2010 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

20th Jul 2025 10:18pm

rich_allen

Member Since: 10 Jun 2016
Location: Rutland
Posts: 21

Yes, calipers all correct, have been fitted for a few years… brakes have just got gradually worse over time to now being non existent..
Will try the manual bleed.
Can anyone tell me how to check/adjust the actuator rod

Thanks

21st Jul 2025 9:33am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17867

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

If you pump the pedal does it go hard?

Assuming you have no leaks then either the m/c doesn't displace enough fluid to apply the brakes, or the m/c is leaking internally and doesn't apply pressure the brake line. If the former, pumping the pedal should give you brakes, if the latter it won't.

21st Jul 2025 10:40am

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