Nightmare job completed.I've had a couple of OEM front calipers for my 92' 110 200tdi for awhile waiting to fit them. The ones we fitted to mine a few years ago were Britpart itmes and I've had nothing but problems with the inboard pistons sticking. The Landrover has a hard life in salt water and sand I was having to strip the front brakes and free the pistons every couple of months and its graduaally got worth.
Armed with the correct replacement bolts and a suitable socket I started work Friday afternoon....... and finished Sunday afternoon.
I tackeld the nearside first and the bottom bolt came out with no issues. The top bolt was corroded and even an Irwin wouldn't grip. I resorted to a cold chisel and lump hammer to try and 'rough' it up enough for the Irwin to grip. After 3 hours I managed to get the bolt out and replace the old calliper with a new one.
Come Saturday morning I set out to tackle the offside thinking it owuld be eaiser as, theoretically, the nearside is always the one in the mud and crap along our lanes. How wrong I was. The bottom bolt came out easily enough. I'm on a roll I thought. Next the top bolt.I couldn't get any purchase on the bolt head and it eventually became so rounded even the cold chisel trick didn't work. I had to resort to using a dremel to cut slots in what remained of the head and then using the chisel to break it off flush with the caliper. I then split the caliper and managed to get drill behind it to drill the bolt hole out to a larger diameter as there is no room to remove the caliper off the remains of the bolt. After a full day I was left with a bolt sticking out of the hub carrier and gave up and had a well earned shower and a few beers.
Sunday saw me applying heat to the stubborn bolt in copious quantities. Mole grips got the remains moving a fraction of a millimetre but eventually I couldn't get any grip as the surface was getting to smooth and theres no room to twist the Mole grips as they get fouled by the hub carrier. I resorted to cross - drilling a hole right through the remains of the bolt shaft and fastening an 8 mm stainless nut and bolt through it. This allowed me to hammer on a suitable sized socket and eventually remove the offending item - 6 hours later! Fitting the new calliper was straight forward and I reverse bled the brakes and took it ofr sa test drive. The braking seems definitely better but what a nightmare of a job. 2 1/2 days to replace 2 calipers that have been on the vehicle for around 3-4 years.
What was surprising is that it was the top bolts that were the ones severely corroded. I'd have expected the bottom ones to be the worst which is why I tackled them first. Thinking about it though the top ones sit in a 'recess' in the calliper that'll hold muck and water whereas the bottom ones, although closer to the muck, are more easily flushed. Whenever I take the Landrover across the beach I always jet wash the underside to get the worst of the salt and sand off but the top calliper bolts are inaccessible.