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Buttercup · 06-29-2012, 08:45 AM

On the way out to International, towing the trailer. We were about 50 miles from the fairgrounds and we heard a "noise" as we were in some stop and go traffic. It was that "metal to metal" sound that can only come from the brakes.

I dialed off the brake controller and gave myself lots of distance and we went the last few miles to International. Sure enough, once we got there and I took a look, the outside forward pad was missing altogether. Now, I don't mean that just the pad was gone leaving only the backing plate. The whole pad was just simply gone, backing plate and all. The retaining pins and clips were still there fastened as securely as when we left.

I have a new set hopefully arriving today at the fairgrounds and I can throw a pad back in to get us down the road and back home. But it seems strange that it would just disappear like that.

In all truth, I did repack bearings and while I had it all open, greezed up all the components with brake lube stuff so I am reasonable sure all was free when I was done and I am 95% sure that the pad was properly seated in the assembly when I was done.

Airslide · 06-29-2012, 09:23 AM

Hey Tim,

Most likely something didnt go back together correctly after the bearing repack. Those pads on that P30 chassis are beefy and that caliper is not going to let them get away under normal conditions. I would think if a pad came loose on the road its going to be an event you wont soon forget.. That pad is heavy and if it slings out of there while driving its going to make a noise! The brakes would also go to the floor upon your next pedal application. Is it possible that pad is still sitting at home in the driveway and after the repack and the initial pumping of the brakes the caliper slid all the way over and the large piston was only putting pressure against one pad? After time it will force the sliding part of the caliper all the way over to make contact with the rotor? Just trying to think it through with you..

Vin

dznf0g · 06-29-2012, 09:28 AM

I'm confused...I think he's talking about one of the trailers.....but a disc upgrade?????

Buttercup · 06-29-2012, 09:38 AM

It was out 27' Overlander and there was no disc upgrades or anything. In fact, all I did was repack bearings and cleaned/lubricated the brakes with standard brake antiseize compound. No other work was done.
I did double check that all went back together prior to putting on each wheel - a sort of double check so that is why I am really, really sure that I got it all back together OK. I didn't want to accidentally grind any metal if you know what I mean.
As far as I could tell, the brakes were working perfectly right up to the end. The damage is not too deep like I had caught it early enough.

Airslide · 06-29-2012, 10:12 AM

Ok my bad.. Glad it wasnt the moho.. I guess when you go back together with the pads you can see if there is any possibility to move the caliper around with a big screwdriver. Something would really have to be worn out for a pad to get away? Glad you caught it early so you can get back to having fun.

Vinnie

dznf0g · 06-29-2012, 10:26 AM

Does a '77 Overlander have disc brakes??? That was the upgrade I was talking about.

Bill M. · 06-29-2012, 11:41 AM

Obviously a pad can come out, since it did. If all the clips are there, I would guess that the pad seperated from the backing plate and came out and then the backing plate fell out of the retaining clips due to all the space between it and the caliper.

dznf0g · 06-29-2012, 11:47 AM

Quote:

Originally Posted by Bill M.

Obviously a pad can come out, since it did. If all the clips are there, I would guess that the pad seperated from the backing plate and came out and then the backing plate fell out of the retaining clips due to all the space between it and the caliper.

But what system DOES make a difference. The Dexter has a pin that runs through a hole in the backing plate (at least all of them I've seen). If it is a "modern" Dexter brake and the pad backing plate is gone....I would think the pin was never installed through the backing plate as it should.

Buttercup · 06-29-2012, 01:35 PM

Quote:

Originally Posted by dznf0g

But what system DOES make a difference. The Dexter has a pin that runs through a hole in the backing plate (at least all of them I've seen). If it is a "modern" Dexter brake and the pad backing plate is gone....I would think the pin was never installed through the backing plate as it should.

The pin was and still is properly installed through the backing plate and the retaining clip is still in place.

I do indeed have the upgraded disc brake option that had the vacuum actuator. I removed it and installed a Dexter E/H actuator.

By the looks of it, the whole thing dropped free. The pad is slightly larger than the caliper backing plate, but the damage to the rotor is only as wide as the backing plate, which indicates to me that the pad dropped free without scoring the rotor.

ROBERT CROSS · 06-29-2012, 01:48 PM

Soundz like your "pads" did the same thing as our "shoes".

Except the shoes did it during the re-pack and not on the rode.

BTW...dexter paid for the replacements.

Bob

Buttercup · 06-30-2012, 10:22 AM

Well, I figured it out. The pad slipped out cleanly and bounced around the wheel a few times before exiting altogether. The cause was the tab on the brake pad bent during braking. Without the tab completely in place, there was nothing to hold it in place.

Part of the problem is that the pads are SO loose in the caliper that they rattle when we go down the road. The brake compound d we put on helped quiet it down a little, but they still rattle. That rattling over thousands of miles have peined the metal thinner and thinner. The strain of braking pushed it to the point of no return.

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See the difference between the remaining pad and the new one.

4RXLA · 06-30-2012, 10:52 AM

The 70's Ausco disc brake pads do rattle in the calipers. I inspect my pads before every trip and will look for this kind of wear. I do carry an extra set of brake pads with me. Hopefully your rotor is not damaged too badly. I hear they are just about impossible to replace.

Buttercup · 06-30-2012, 11:12 AM

Quote:

Originally Posted by dougsale

The 70's Ausco disc brake pads do rattle in the calipers. I inspect my pads before every trip and will look for this kind of wear. I do carry an extra set of brake pads with me. Hopefully your rotor is not damaged too badly. I hear they are just about impossible to replace.

The rotor is actually not too bad. I think I caught it early enough, like right after it happened.

The Dexter guy said he would be happy to put new equipment on my trailer, for a price!

Oh, before I forget, I snapped off a stud when tightening the wheel back on.

Buttercup · 06-30-2012, 11:15 AM

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The rotor is not too bad in my opinion.

Airslide · 06-30-2012, 10:42 PM

Glad you identified it Tim. Something had to be worn out.. Im glad it was the pad and not the caliper.

Schu · 07-01-2012, 06:01 AM

Quote:

Originally Posted by Buttercup

The rotor is actually not too bad. I think I caught it early enough, like right after it happened.

The Dexter guy said he would be happy to put new equipment on my trailer, for a price!

Oh, before I forget, I snapped off a stud when tightening the wheel back on.

I am glad you have gotten it figured out.it was nice getting to talk with you at the Rally!

Schu

Buttercup · 07-01-2012, 06:29 AM

Quote:

Originally Posted by Schu

I am glad you have gotten it figured out.it was nice getting to talk with you at the Rally!

Schu

Thanks! It was good talking to you as well. With this experience, I am thinking about some modifications to my brake system to keep those pads from chattering do much and mushrooming that metal backing plate. Brake grease alone is obviously not enough.

One big lesson for me is not over tightening your wheel lugs! It appears I did that without evening knowing it when I snapped that one off. Not going to carry a torque wrench with me on the road but it would be a good idea to at least know what an appropriate amount of torque is appropriate and what is too much.

Buttercup · 07-08-2012, 11:33 AM

Just an update. We are making our way back home and discovered that we lost another pad. We also have one that looks like it is ready to drop.
My brother looked at it and discovered that the clevis pins holding the pads in place are worn and loose, compounding the problem. So, we are once again driving without trailer brakes.

Buttercup · 07-09-2012, 06:11 PM

Just as I suspected. We stopped because we heard a strange sound. I replaced the missing pad and the one about to go. As you can see, the tab is bent. It almost seems like the pads cannot handle the strain....
I got these from Inland RV. I was told they are custom made for Andy. If you are out there Andy, maybe you can tell me more about these pads.

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4RXLA · 07-09-2012, 06:56 PM

Buttercup, there is something dragging somewhere. Loose pins would not cause that kind of distortion to the pad clasp in my opinion. The pads sit loose on the pins and rattle and chatter around until the brakes are applied and the piston pushes the pads against the rotor. An extreme force is bending the clasp. Normal braking would not do that. Are your calipers and spacer bars properly installed?