2001 Berlingo brake problems

[Martinez]

2001 Berlingo 2.0 hdi
My brakes have never been great, but whilst away on hols last week a grinding noise developed (sound like no front) and warning light came on dash. Can’t see any leaks but reservoir was empty so filled it up. Light went out but still grinding noise
I’ve taken front wheels off this morning to find both discs and pads look fine !
I serviced these brakes less than 3K ago and they look the same as back then.
I’m thinking to just replace discs n pads to see if there’s any improvement, but where’s the fluid going ?

[wheeler]

If its a hydraulic clutch check the slave cylinder & pipework too as they will share the reservoir. I suspect you will have a cable clutch though on this age.
Failing that its normally fairly easy to spot a brake fluid leak, get someone to pump the brake pedal whilst you have a look. Has the fluid gone down at all again since topping it up?

[Martinez]

Don’t think so, I did check it on way back and all seemed ok. But weirdly, when I rebuilt the rear brakes couple of years back, I had to top fluid up by quite a lot back then + adjust the handbrake. I would’ve expected the opposite. I’ve kept an eye on it since and level has been fine.
Although the manual states minimum thickness of discs is 19mm, spec on new discs states 20mm. Mine are around 19.5mm so time to change them. Euro car parts stated they had them in stock, but after driving all the way there they don’t !
Bloody useless. I’ve ordered some to collect tomorrow morning, just in time for hottest part of day. Can’t wait eh

[Paul-R]

Do you not have a GSF or some better motor factor nearby? ECP really don't deserve custom for such poor service. They're not known as Euro Crap Parts for nothing.

[Martinez]

Collected discs n pads this morning. But could I get the caliper brackets off ? No way. Even my impact driver failed to undo those huge torx bolts. The discs supplied were only 20.5mm thick not 22mm like I was expecting. So I’ve put the pads in which has stopped the scraping noise. But tbh the brakes are still poor. I certainly can’t lock the wheels up regardless of my 17 stones on the pedal.
Whilst fitting new pads, I noticed that with the new pads in there was more of a gap than I’ve usually experienced. Also, the caliper piston on the NSA’s which was noisy was extended to what I’d think was pretty much its maximum. So I’m thinking the brakes failing and the scraping noise may have been due to the caliper not being able to provide any more movement.
The pads all still have between 6 and 10mm of friction material on them, hence my thoughts that the discs should be 22 Mm.
Ive had issues before with my van as it’s a 2001 which seems to have some 2002 parts. Euro crap have said they have the discs back if I’m not happy, but the guy on the counter insisted they are correct. I’m yet to be convinced, but how can I confirm this ?

[Martinez]

Oh, and I had to bleed off quite a lot of fluid, which maybe explains where it all went ?

[Martinez]

I suppose then I’ll have to do the job I’ve been avoiding, bleeding the system. Any idea how much Dot 4 I should buy ? 500ml enough ?

[Rp0thejester]

I can recommend WD-40 penetrating oil, it worked for me, I'm sure other penetrating oils will work just as well to remove the brake caliper bolt.

[Martinez]

I did give them a soaking with penetrating oil, but still couldn’t budge them. Might have to get some heat on them

[Rp0thejester]

Heat should not needed, regular spraying should work, heat near brake pads always worry me......

[PaulC5]

On our Cactus and previous C3, the caliper support bolts were 105 Nm and 55 torx bit. To undo them needed a long bar so if your bolts are a similar torque then no wonder you are struggling to undo them. I think they might also have loctite on them but could be wrong.

[Martinez]

Undoing the bolts is the least of my problems. Knowing I’ve got correct discs is my priority. The ones fitted are around 19.5mm thick and in decent condition. But new ones supplied are only 20.5mm and I think they need to be 22mm.
How to I check for right parts ?

[Martinez]

Today I finally replaced the brake fluid. I bought one of those vacuum things off eBay, but my small compressor wasn’t really up to the job so I resorted to getting the Mrs to work the brake pedal whilst I did the messy bit. Final result shows little improvement tbh. So, my suspicion is moving towards the brake compensator. The spring was broken when I got it so I bought a stainless replacement part online. I’ve never been 100% happy with the setting on this. Garage adjusted it at my request which did improve things but I just don’t seem to be getting enough going to the front.
Tonight I tried the brakes in reverse and they stop much better than going forwards !

[Martinez]

Been a while and van was Sorn, but took it to mechanic on Thursday to check brakes. He jacked it up and got underneath, but said no signs of any brake fluid leaking out.
So now I’m thinking Master cylinder leaking into servo. Anyone else had this ? Would I need to remove servo to clean it out or can it be drained in situ ?