I had a hard time getting the air out (standard bleeding) when I replaced everything on mine. Before I got all the air out, it didn’t brake well at all. I have never had issues getting air out with any other vehicle. I don’t know why the D1 is so difficult. My wife had to alternate from right to left leg and was less than thrilled as my assistant.
With the NAS D90 calipers and vented discs, new standard D1 rear calipers, middle of the road Bendix brake pads (not too hard, not too soft), stainless hoses, TRW master cylinder, and a lot of effort in bleeding, it stops as well as any SUV I have owned. (I also discovered I didn’t put enough preload on the wheel bearings causing loss of brake pedal sporadically.)
I also have a new TRW servo yet to be installed. As far as fixing things that are not broke, yes, I probably did in a few aspects. However, with 21 year old brake parts going from 9000‘ elevation to 5000’ on a regular basis as well frequently traveling narrow roads with no shoulder and steep drop offs on the sides, the relatively small amount of money spent replacing a few extras was something I wanted to do. Furthermore, it was a lot less time doing it “while I was in there” than taking it apart later due to a failure.
Also, after reading posts here, for a few reasons when the Bendix pads wear out I expect to give the OEM pads a try and see if any improvement is noticeable.
In my previous experiences what I found most important was to avoid really hard pads, for example anything with a lifetime warranty, and really soft pads which were usually the cheapest and “non-metallic” and “quiet” option.
When I was a teen I worked in an old fashioned parts store. When pads were returned it was 90% percent because the “quiet” pads wore out too fast and the ”semi-metallic” pads were noisey. The remaining 10% was due to making the wheels too dirty with dust from the pads.
By the way, the tires my D1 came with were barely worn and looked fine, but were 11 years old. I put new tires on...
The D1 will eventually be my daily driver when I move to the mountain in about 18 months.
It isn’t my daily driver now and I could let it sit while I slowly found time to work on it and figure out the overall best way to address current problems and hopefully prevent future problems.
My daily driver now is a 2017 GMC Canyon 4x4 with a 2.8 diesel. It is great but the D1 is a lot more fun and better on those narrow mountain dirt roads.