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Disco Dave III
Member Since: 29 Sep 2024
Location: Farnborough
Posts: 6
  
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| 2009 Disco 3 - Restoration & Issues |
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Hi, new to the forum, but have been using it to learn about the Disco 3 over the past few months. It's been a great source of information, so thankyou, all.
So, I'm more or less new to vehicle mechanics and maintenance, and Land Rover D3s in general. But, I now own one and am in the process of getting her in good shape so that all 4 wheels are back on the road.
In the last couple of months, I've fixed a number of the issues:
- Replaced the EGR valves
- Cleaned out the Intakes and Intake manifold
- Replaced the Actuators, Latch and Switch for the rear tailgates etc
- A load of other things...
But, I handed my D3 over to a local garage that was near to me, supplying the parts for the repairs.
This included a complete set of brake discs, pads, callipers and calliper carriers for all wheels - thinking she would be returned and fully working.
Since picking up the car, I've noticed a number of issues:
- Smoke coming from the bonnet - turned out to be a loose radiator top hose. [Fixed]
- Burning acrid smell - Identified today as 4 hot wheels, and smoke coming from the front brakes.
- Rumbling / vibration coming from below the drivers seat, central area. (started happening after stopping slowly from 35mph 3 times in a row.)
- Squeaking - Coming from front and rear brakes. (same as above)
The intention today was to drive out and bed the brakes in, but I've not come across this heat and smoke before. Now, I hear this could be calliper sliders not greased properly, or not sliding, also sized calliper cylinder. But, the brake system is new - fresh on. I've not had her up on the jack yet to get the wheels off and take a look. But, would like some ideas as to why this may be happening.
Keep in mind, this is a brand new set of brake kit... 
Any ideas as to what may be causing this issue with the brakes and wheel heat?
I tested the EPB on a hill - put her in neutral and she rolled down fine, no sticking or squealing sounds.
Any advice is very thankfully received.
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 29th Sep 2024 5:53 pm |
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Disco Dave III
Member Since: 29 Sep 2024
Location: Farnborough
Posts: 6
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So, after doing additional research into this issue it looks like it could also be worn wheel bearings.
Based on the fact she was left sat in a field for a while, I'm going to replace them all.
Have ordered the new parts, including parking brake replacements for the rear wheels.
I will see if this fixes the issues over the coming weekend.
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| 30th Sep 2024 9:02 am |
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Pete K
Member Since: 15 Jan 2016
Location: GL
Posts: 10732
 
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Did you drive the car fully before you took it to a garage? were the brakes ok?
This is an issue of supplying parts to a garage. They won't want to help fix and you weren't able to test drive inbetween parts being fitted.
Has the brake servo been replaced recently? That could cause those symptoms.
Take one front wheel off, push the brake pads back a bit. Then check the calliper slides freely.
Press the brake pedal to close the gap up again.
I expect a lot of discos Squeel their brakes
Another issue could be blocked rubber brake hoses. (if you draw a blank you could try replacing the front ones)
Also try driving the car from cold, but first press the DSC button on the center console so that an orange light is lit on the dash. Drive like that and see if the brake still over heat and that you have judder
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| 30th Sep 2024 9:39 am |
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Disco Dave III
Member Since: 29 Sep 2024
Location: Farnborough
Posts: 6
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Hi Pete, thanks for the advice, much appreciated.
So, just popped out for a quick spin with the DSC turned off, as you suggested.
Not too long a trip, possibly 6 miles in total, with speeds ranging from 20 to 60mph.
Noticeable differences: [DSC off]
- She rolls to a stop when the foot is taken off the gas, gently
- No burning smell on returning home
- No smoke coming from the brake pads
- Discs were hot to the touch
- Alloys & Tyres were not hot
- Engine seemed more comfortable, especially in terms of gear change and revs
- The sound of cooling metal was noticeable near the wheels
- She drifts to the left if you take hands away from the steering wheel
- Some brake discs have a bright orange splatter on them, similar to rust.
Prior to brake overhaul:
- Driver side front brake was binding
- Heavy rev and skittish gear changes
- Take the foot off the gas and she shopped as is brakes were applied
- Brakes were in a bad condition: 90% wear on rear and 80% on the front.
Will investigate some more in the coming days...
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| 30th Sep 2024 12:57 pm |
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Pete K
Member Since: 15 Jan 2016
Location: GL
Posts: 10732
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Well I guess you need to try again, to see if it really is DSC related or coincidence
The DSC can brake each wheel individually (by itself). It DSC is causing issues it may need:
Steering angle sensor calibrated
Tyre pressures checked.
Can be caused by 1 seized calliper (bit of a circle that one!)
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| 30th Sep 2024 1:20 pm |
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Disco Dave III
Member Since: 29 Sep 2024
Location: Farnborough
Posts: 6
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So, managed to take a look this weekend. Think I've found the issue. But, as of yet unable to test.
Seems like the Brake clips on the caliper are really tight. So, when the brake is applied, the pads remain in place, or in contact. The mechanic, who is based in Farnborough seriously needs to check his work. When I jacked her up, the drivers side front wheel was basically hanging off.
For safery, I shall look at all 4 wheels and double check everything that has been done. Frankly, I'm in shock that this is what you pay for at a garage.
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| 6th Oct 2024 4:53 pm |
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Disco Dave III
Member Since: 29 Sep 2024
Location: Farnborough
Posts: 6
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So, here is what we have so far:
- front wheel assembly replaced
- Rear wheel knuckle and bearings replaced
- front and rear brakes hoses replaced
- Rear wheel parking brake shoes and parts replaced
- all calipers checked cleaned and pads greased
- all disc brakes cleaned
- some abs sensors replaced.
Result: discs and wheels still heating up.
- need to bed the parking shoes.
- driven again with dsc off - less heat, super quick acceleration
- need ro have balancing redone
- tyres will need to be replaced, slow leak from left side front t and rear.
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| 19th Oct 2024 8:05 pm |
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Disco Dave III
Member Since: 29 Sep 2024
Location: Farnborough
Posts: 6
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Narrowed the issues down and replaced the Brake master and Brake Servo. Bled the ABS Module, and so far the wheels are cold, even after an hour of driving. Guessing the caliper pistons were not fully retracting.
Picked up an IID Gap tool and found an error code pointing to a failing ABS module. Which might explain why the brake pedal still sinks after starting the car with the foot resting on the pedal. Replacement on the way.
As annoying as this can be, I can't help but enjoy fiddling with the bloody thing.
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| 5th Nov 2024 11:13 pm |
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