Noticed the other day when I went wheelin and shootin (Saturday) that my rear brakes were being noisier than usual. The back driver side to be exact. Figured it was a rock or dirt caught up in between the rotor and pad etc.. Finally got to look at it today (haven't driven her since Saturday) and long behold, the inboard pad was down to bare metal. The inboard side of the rotor was ate to shyt! Outboard pad has 3/8+ inch left and rotor is smooth as glass. Looks like the inboard caliper piston got stuck in the out position and wore the pad down prematurely thus making the rotor into caca. .

Anyways... Ordered rear new rear pads ($18) and rear rotors ($30ea) from O'reillys. Great price so just gonna change both out (company account). Parts should be here tomorrow and they're going right in. Front looked good so I'll do those later in the year. I tore down both rear calipers, cleaned them up, replaced o-rings and reassembled. Op checked them with air comp, both slide in and out smoothly...

I tell ya.. These Rovers are money pits but they're so fun and easy to work on! Love my Disco 1...

 

more pics... I'll post more when new parts come in.

 

I'm with you on rebuilding calipers. The "new" $95.00 cheap-o gold calipers(like SMC500110) that everyone sells are scrap. Hope you remembered to replace the channel/bridge seal in pic 3.

 

What's that ring/seal around the axle?

 

FTC5268 > Hub Oil Seal With ABS - Rear (FTC5268 Same Fit As Part # FTC5268 ) - Land Rover gaskets and seals from Atlantic British
When you get diff fluid mixing with the wheel bearing grease that's the seal that is the problem.

 

Yup, replacing that seal in the caliper and axle seals on both sides. Seals should be in tomorrow along with correct pads... They gave me D2 pads. Rotor was the right one at least. Just swapped the gun and gear thing from the old one to new one. All in all, I'm in it with all new parts for just under $90. Not bad for a full rear brake job and axle seals.

 

If you off-road (actually, even if you don't) you want to use RTC3511 hub seals, not the ones listed for the disco.
RTC3511's are double lipped and keep grease/oil in better out keep dirt and water out better.

 

Truth.

 

I got whatever seals come up at O'reillys. Got everything all buttoned up, bled and bedded. Brakes feel way better now. I was gonna wait to do the fronts but I might as well do it this weekend or next. I'll also inspect/rebuild the calipers while I'm at it.

 

Well next time you're O'Reillys ask for the seals for a '97 D90.

I just keep a healthy stock of brake/hub parts on hand. Hub seals, drive flange gaskets, lock washers, etc. Then I always have them if I need to mess around. My local Rover friends know I have them and will grab some in a pinch which is cool, I just ask they replace them with the same thing when they can.