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Fleagle_UK
Member Since: 10 Jul 2009
Location: England
Posts: 86
  
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| Gonna replace master brake cylinder and Servo -any pointers? |
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I'm fairly mechanically minded and experienced so the task doesnt worry me but just wondered before I start does anyone know if there is anything peculiar to the D3 and doing this job ? any special tools needed etc, any adjustments that need to be kept. If anyone has experience or instructions or can point me in the direction I would be grateful.
Thanks
fleag.
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 29th Apr 2010 8:59 am |
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Fleagle_UK
Member Since: 10 Jul 2009
Location: England
Posts: 86
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just an update on the job so far.
spent just an hour and half this morning. Still a bit more to do but I was surprised just how easy the work has been so far.
First cover ALL paintwork...too much risk of brake fluid splashing around which will kill any paint work!!!!
Drained all fluid from reservoir
Slacken off brakeline outputs (x2) that lead to ABS unit
Undo Master cylinder just 2 bolts
Pull hard on master cylinder to separate from servo
disconnect servo vacuum pipe (trace signs of oil in there!)
Move to driver foot well, undo four mounting bolts for servo - 3 easy to get to - top right one was a bit awkward
Slide out pin from brake pedal to push rod (clip on righthand side - easier to get to if you push the brake pedal down)
Unbolt brake line outputs (x4) from ABS unit and 3 mounting bolts to inner wing from mount and move to one side
Remove alarm sounder (2 bolts) - (This has VOLVO stickers all over it !!!)
Remove plastic base (in 2 parts)
Servo slides out easy...and guess what ? .....it was full of oil !!!
New master cylinder and servo fit in reverse of above plus the revised (as per recall) vacuum pipe arrangement (can be a bit fiddly inserting valve for secondary vacuum input (remove blanking plug first) - not much room to get fingers in and becareful not to loose the new spring and valve when you insert it !!).
All bolted together re assembled. Just now need to bleed and test the system. Will do that tomorrow (weather permitting) and I'll report back how it all went.
Cheers
Last edited by Fleagle_UK on 21st Mar 2012 5:52 pm. Edited 1 time in total
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| 1st May 2010 5:57 pm |
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Bodsy
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Member Since: 06 Nov 2006
Location: In the Clubhouse
Posts: 21361
 
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Sounds like a job well done 
any reason why you didn't get th recall done under warranty ? Bodsys Brake Bible
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| 1st May 2010 6:25 pm |
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Fleagle_UK
Member Since: 10 Jul 2009
Location: England
Posts: 86
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Bodsy wrote:Sounds like a job well done
any reason why you didn't get th recall done under warranty ?
believe me I tried. But since my chassis number is before that published by Landrover, they told me they would have nothing to do with it unless I paid them. 
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| 1st May 2010 6:28 pm |
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DN
D3 Decade
Member Since: 24 Jun 2006
Location: W.London.
Posts: 2294
 
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I think a report and any supporting info (pics etc) should be sent to VOSA. LR shouldn't be shunning this, whatever VIN's they think are affected, they obviously haven't a clue.
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| 1st May 2010 6:57 pm |
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Fleagle_UK
Member Since: 10 Jul 2009
Location: England
Posts: 86
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Sorry I have to write this but....
Given the nanny state we live in these days, I guess I should add that these are just my findings for my level of skill and competency. Given that these are the cars brakes we're are talking about i.e. the most important system on a car some might say  , then if you are at all unsure or not capable of the doing the work yourself, then seek professional advice or let them do the work for you!
I dont want someone knocking on my door trying to blame me coz they wiped out some poor soul on a zebra crossing after their brakes failed 
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| 1st May 2010 7:38 pm |
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buda
Member Since: 24 Jan 2010
Location: strathclyde
Posts: 334
 
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oil in the servo is a problem idendtified by landrover already, but even if its out of warranty or not subject to the recall given the chassis number, the  should still pay. not only that they should expand the recall program to include all other affected models. if someones crashes because of poor brake response or failure, they should be liable........ :the censored:
Vosa should be informed so they can apply pressure to them before anything tragic happens........what else can we do...?
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| 2nd May 2010 12:02 am |
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caverD3
Member Since: 03 Jul 2006
Location: Oberon, NSW
Posts: 6922
  
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Agree, problem should be fixed by LR.
If you asked your dealer they can try to get LR to pay. LR Aus are paying out of warranty fixes for it.
Is that why you replaced them? “There are only three sports: bullfighting, motor racing, and mountaineering; all the rest are merely gamesâ€
Ernest Hemmingway
D4 3.0 Active Diff, Adaptive Lights, High Beam Assist, Surround Cameras, Privacy Glass.
D3 2.7:Adaptive Headlights,Electronic Rear Diff,ARB Bar,Blaupunkt Speakers,JVC Powered Subwoofer,Removable Snorkel,Mitch Hitch,Pioneer After Market Head Unit,Steering Wheel Control Adaptor,Remote Adjustable Supension Rod System, Taxside Dual Battery System.
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| 2nd May 2010 2:38 am |
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Roger 47
Member Since: 25 Oct 2008
Location: Exmoor Somerset
Posts: 58
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Useful information, well done. What was the parts cost and where they all stock items. 1988 Range Rover
1990 Range Rover
1993 Range Rover
2001 Freelander GS
2002 Discovery TD5 ES
2005 Discovery 3 TDV6 S
2007 Freelander 2 S
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| 2nd May 2010 11:29 am |
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Fleagle_UK
Member Since: 10 Jul 2009
Location: England
Posts: 86
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just finished bleeding brakes. (Did them twice just to be sure)
All good !
I finally have working brakes again that stop me on a sixpence (well ...as much a 2.7tonne car can be  )
All parts are original LR parts. Nick (aka "The large one") came up trumps as usual. (thanks nick!)
Just one further point while doing the work, make sure you keep all areas that come into contact with brake fluid clean so as not to contaminate the fluid.
Last edited by Fleagle_UK on 21st Mar 2012 5:52 pm. Edited 1 time in total
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| 2nd May 2010 12:10 pm |
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caverD3
Member Since: 03 Jul 2006
Location: Oberon, NSW
Posts: 6922
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Did you replace the vacuum line according with modified parts and fit according to recall?
If you didn't then it will happen again. “There are only three sports: bullfighting, motor racing, and mountaineering; all the rest are merely gamesâ€
Ernest Hemmingway
D4 3.0 Active Diff, Adaptive Lights, High Beam Assist, Surround Cameras, Privacy Glass.
D3 2.7:Adaptive Headlights,Electronic Rear Diff,ARB Bar,Blaupunkt Speakers,JVC Powered Subwoofer,Removable Snorkel,Mitch Hitch,Pioneer After Market Head Unit,Steering Wheel Control Adaptor,Remote Adjustable Supension Rod System, Taxside Dual Battery System.
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| 2nd May 2010 12:53 pm |
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anglefire
Member Since: 09 Mar 2010
Location: In the Club House
Posts: 4180
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Well, it said in his post that he did! Mark.
2006, D3 SE Auto - gone but not forgotten.
2014 BMW 530d M Sport Tourer.
1977 Triumph Spitfire 1500
_________________________________________________
Disco Picture Website Here
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| 2nd May 2010 4:12 pm |
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Fleagle_UK
Member Since: 10 Jul 2009
Location: England
Posts: 86
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caverD3 wrote:Did you replace the vacuum line according with modified parts and fit according to recall?
If you didn't then it will happen again.
yep, new shiny vacuum pipes installed as per the recall.
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| 2nd May 2010 4:36 pm |
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caverD3
Member Since: 03 Jul 2006
Location: Oberon, NSW
Posts: 6922
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 Must learn to read.  “There are only three sports: bullfighting, motor racing, and mountaineering; all the rest are merely gamesâ€
Ernest Hemmingway
D4 3.0 Active Diff, Adaptive Lights, High Beam Assist, Surround Cameras, Privacy Glass.
D3 2.7:Adaptive Headlights,Electronic Rear Diff,ARB Bar,Blaupunkt Speakers,JVC Powered Subwoofer,Removable Snorkel,Mitch Hitch,Pioneer After Market Head Unit,Steering Wheel Control Adaptor,Remote Adjustable Supension Rod System, Taxside Dual Battery System.
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| 3rd May 2010 1:51 am |
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Roger 47
Member Since: 25 Oct 2008
Location: Exmoor Somerset
Posts: 58
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Thanks Fleagle for the PM. I don't have a problem as yet but has anybody have any thoughts on whether to carry out the pipe mod only if everything else is ok.  1988 Range Rover
1990 Range Rover
1993 Range Rover
2001 Freelander GS
2002 Discovery TD5 ES
2005 Discovery 3 TDV6 S
2007 Freelander 2 S
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| 3rd May 2010 10:13 am |
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