01-03-2025, 09:32 AM
I've a 2006 1.6HDi Combi. I've had several problems with front brake callipers (apparently) but with the latest occurrence wonder if there is more to it. I'll try to summarise:
Bought the vehicle in 2020, with 80k miles. Disability conversion, appeared well looked after. A couple months into ownership had a problem where the nsf calliper stuck on. Replaced the calliper and, as good practice, replaced the osf at the same time. I don't now recall exactly the detail but there must have been a recurrence of a similar problem thereafter since I received some advice that my mechanic acted on - best he can recall from 5 years back:
"If I remember rightly, I undid the fluid reservoir, pulled it away and slightly turned the rod to gain a little more free play. I don't recall if it was under the dash connected to the pedal, or possibly needed access both places". Whilst not very specific, you get the gist and maybe someone will recognise exactly what...
(This tip was given to me by a classic car garage which was working on on old sportscar of mine).
Anyway, it worked well, and cured the problem.
Fast forward to September 2023, ie three years later and probably 15k miles further, and a recurrence - this time the osf brake seized on. This was however in the freakish heatwave we had and it was 35-deg C at the time. A contributing factor? (it likely didn't help).
The night before leaving for holiday, it left us marooned, and I had it attended to whilst we were away (another calliper, to the osf).
Then, a couple of weeks ago, another 9k miles; and I experienced an unusual vibration through the steering, as if a front wheel had lost a balance weight....but very oddly, 'coming and going' ...for want of a better description, at 50mph "on" for 3 seconds and "off" for 3 seconds, repeating. I was half a mile from home so decided to continue steadily down the quiet rural road. When stopped, I could smell brake material and, sure enough, the nsf this time was hot. Let it cool down, lifted the front and the brake was virtually seized. Another calliper.
So, that's two on each since over the course of c. 20k miles and five years. Vehicle is used every few days for a journey of 10-25miles, typically, by the way.
The last calliper was replaced a fortnight ago.
Since then, I noticed an intermittent, subtle but definite vibration, seemingly from the front of the vehicle. Similar to driving along and the road surface changes to a more uneven one. Can't detect a pattern, but does seem (slightly) greater at c 50mph. Had two experienced mechanics drive it without describing in detail and both fedback similar observations. But no suggestions beyond checking the basics (loose wheel, etc etc...all done)
On jacking the car yesterday, the nsf wheel is dragging compared to the offside front. Whilst not scientific, to illustrate the difference, approximately the same for exerted to spin the wheels one at a time results in the offside doing 3-4 revolutions, the nearside barely one revolution.
I contacted the manager of the motor factors who have supplied the callipers - in 6.5 years he's been there, they have never had one front calliper returned faulty.
I must admit it seems like there could be an underlying issue.
The vehicle is kept in good condition and brake pads are about a third worn, when replacing them or the callipers everything is given a good clean, slide pins replaced if needed, the discs were replaced with the callipers first time and have no nasty lips (etc.). I can't be absolutely sure, but I believe we replaced the hoses the first time, too, in case there was a weak one.
I wonder if anyone has experienced anything like this?
Or can suggest further tests to try to establish what's going on pls? (especially at the master cylinder end).
Many thanks
Rob
Bought the vehicle in 2020, with 80k miles. Disability conversion, appeared well looked after. A couple months into ownership had a problem where the nsf calliper stuck on. Replaced the calliper and, as good practice, replaced the osf at the same time. I don't now recall exactly the detail but there must have been a recurrence of a similar problem thereafter since I received some advice that my mechanic acted on - best he can recall from 5 years back:
"If I remember rightly, I undid the fluid reservoir, pulled it away and slightly turned the rod to gain a little more free play. I don't recall if it was under the dash connected to the pedal, or possibly needed access both places". Whilst not very specific, you get the gist and maybe someone will recognise exactly what...
(This tip was given to me by a classic car garage which was working on on old sportscar of mine).
Anyway, it worked well, and cured the problem.
Fast forward to September 2023, ie three years later and probably 15k miles further, and a recurrence - this time the osf brake seized on. This was however in the freakish heatwave we had and it was 35-deg C at the time. A contributing factor? (it likely didn't help).
The night before leaving for holiday, it left us marooned, and I had it attended to whilst we were away (another calliper, to the osf).
Then, a couple of weeks ago, another 9k miles; and I experienced an unusual vibration through the steering, as if a front wheel had lost a balance weight....but very oddly, 'coming and going' ...for want of a better description, at 50mph "on" for 3 seconds and "off" for 3 seconds, repeating. I was half a mile from home so decided to continue steadily down the quiet rural road. When stopped, I could smell brake material and, sure enough, the nsf this time was hot. Let it cool down, lifted the front and the brake was virtually seized. Another calliper.
So, that's two on each since over the course of c. 20k miles and five years. Vehicle is used every few days for a journey of 10-25miles, typically, by the way.
The last calliper was replaced a fortnight ago.
Since then, I noticed an intermittent, subtle but definite vibration, seemingly from the front of the vehicle. Similar to driving along and the road surface changes to a more uneven one. Can't detect a pattern, but does seem (slightly) greater at c 50mph. Had two experienced mechanics drive it without describing in detail and both fedback similar observations. But no suggestions beyond checking the basics (loose wheel, etc etc...all done)
On jacking the car yesterday, the nsf wheel is dragging compared to the offside front. Whilst not scientific, to illustrate the difference, approximately the same for exerted to spin the wheels one at a time results in the offside doing 3-4 revolutions, the nearside barely one revolution.
I contacted the manager of the motor factors who have supplied the callipers - in 6.5 years he's been there, they have never had one front calliper returned faulty.
I must admit it seems like there could be an underlying issue.
The vehicle is kept in good condition and brake pads are about a third worn, when replacing them or the callipers everything is given a good clean, slide pins replaced if needed, the discs were replaced with the callipers first time and have no nasty lips (etc.). I can't be absolutely sure, but I believe we replaced the hoses the first time, too, in case there was a weak one.
I wonder if anyone has experienced anything like this?
Or can suggest further tests to try to establish what's going on pls? (especially at the master cylinder end).
Many thanks
Rob
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