Brake Booster failures on Discovery I

efacewin

efacewin

Member
Jun 11, 2017
20
0
SC
My first brake booster lasted for 275K miles and 25 years. 2 replacements have failed in the last 5K miles in 1 year. First replacement was new but of unknown origin. Second one came from England and billed as the best replacement. (While it lasted it seemed to work as well as the original). Any suggestions?
 
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Steve M

Well-known member
Mar 11, 2005
107
2
I had a TRW one put in as the master was leaking into it. Also did the D90 front caliper & rotor conversion. The brakes are really strong now!
 
Knightspirit

Knightspirit

Well-known member
Sep 22, 2019
251
84
Mount Shasta, CA
Steve M said:
I had a TRW one put in as the master was leaking into it. Also did the D90 front caliper & rotor conversion. The brakes are really strong now!
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Was this on a D1? I am looking on the TRW web site and there is nothing there for a D1 as far as a booster. I want this set up also - my brakes are not great...
 
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DiscoClay

DiscoClay

Well-known member
Mar 18, 2021
437
86
Chapel Hill, North Carolina, USA
efacewin said:
My first brake booster lasted for 275K miles and 25 years. 2 replacements have failed in the last 5K miles in 1 year. First replacement was new but of unknown origin. Second one came from England and billed as the best replacement. (While it lasted it seemed to work as well as the original). Any suggestions?
Click to expand...
I am in the process of making a hydraulic conversion. I have had the same experience... and even when they work... they are for sh!te. The conversion is using the hydraulic booster from the venerable 1999-2003 (and many more) Ford Powerstroke diesel pickup truck. I am not quite done with the conversion adapter (it's taking some time to craft it via Fusion 360, CNC and all that), once I am, I will report back to my prior thread on the topic.
 
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efacewin

efacewin

Member
Jun 11, 2017
20
0
SC
Thanks. I am very interested. I just got your response . Will try to check back regularly . If you can, send me a direct msg to help me see it immediately. Thx.
 
efacewin

efacewin

Member
Jun 11, 2017
20
0
SC
PS. My theory is that all of these standard replacements may have been sitting on a shelf since the 90s and the rubber parts are failing due to age. Sound plausible?
 
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discostew

Well-known member
Sep 14, 2010
7,713
1,016
Northern Illinois
We replace them here in the states too. It takes a tool that holds the booster and clamps down to overcom the spring inside it. then a big bar turns the two halfs to seperate them.
 
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