I've been restoring my 03 Disco and need some advice or direction on the brakes. All braking components have been replaced - brake lines, brake pads, rotors, a couple calipers (not all), the ABS master cylinder and ABS module (rebuilt and reprogrammed), couple fluid flushes, etc. But the brakes are still extremely weak. I owned one of these new and know it's a far cry from what it should be. You can push the brake pedal as far as it'll go and the car comes to a slow stop. There's absolutely no activation of the anti-lock braking...no way it comes close to being able to lock up the wheels. The only thing left to replace is the brake booster, which you can't find a new or aftermarket part there. I did just order one on eBay that's used but said to be in good working condition...along with the brake booster vacuum line and intake host fitting, just for good measure.

Does anyone have anything other input on this? I've got some other things to throw around regarding my restoration process but figure this'll be a good conversation starter.

 

You may need to do a power bleed.

 

there are probably air bubbles caught in the ABS module. do you have a scanner that can bleed the module?

 

Firm pedal or is it soft? Vacuum test your booster and see if it holds vacuum overnight.

 

Do the ABS bleed by shorting the relay. You will need to bleed the module, then lines and repeat b/c it will be pushing air towards the calipers.
Also follow the correct bleed order described in rave

 

Have you replaced the vacuum booster? Had to change mine twice. When it's bad, the pedal is firm, but brakes are weak.

 

Also check the RAVE manual for the proper order to bleed from the calipers.

 

Yeah, I’m on the bleeding procedure. Did you use something to cycle the ABS pump? If you’ve replaced that much, it’s almost certainly a few bubbles in there.