AndrewW
Member Since: 06 Aug 2007
Location: Saddleworth
Posts: 2302
  
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I'm going to have to get clever enough  to put the 12megapixel original photos somewhere for folk to look at....
Hope to answer all questions soon. I will be very surprised if the internals of the gearbox and clutch - if it exists - are something we can mend / service / replace, but I shall be looking out for that...
I think it would seal back up afterwards - a load of gooey caravan sealant should do it! The lid fixes/unfixes with 8 Torx ST screws. Like they INTENDED to get back in there...
A 2006 D3 finally swapped for a 2016 D4 Graphite in Graphite grey. No mods
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 18th May 2010 11:52 pm |
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AndrewW
Member Since: 06 Aug 2007
Location: Saddleworth
Posts: 2302
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Got the answers!
Will take a while to get the words simple and accurate, and the pictures labelled / arrowed and uploaded.
In essence there IS an overtorque clutch which has failed - and failed through poor design!!!
Everything else is beautiful and Germanic - the failed bit is evidence of the bean-counters influencing production engineering. So sad. Their 20p saved costs you £400-£600 of replacement EPB system.
Watch this space..................... 
Andy 2006 D3 finally swapped for a 2016 D4 Graphite in Graphite grey. No mods
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| 5th Jun 2010 11:38 pm |
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DiscoJools
Member Since: 31 Jan 2008
Location: Mornington Peninsula
Posts: 132
 
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AndrewW
Looking with interest at your EPB descriptions. Had a screamer a long time ago, seemed it was not adjusted correctly at service. Since then have done a couple of desert trips here in Aus. Both times (and the other D3 that i was with ) had flashing EPB red warning light on dash after a certain amount of time in the sand and dust. Could get rid of it by applying and releasing the EPB. This happenned constantly thru the trip and in the end I decided not use the EPB in case it stuffed up altogeter. The other D3 had his complete handbrake changed after the trip under warranty. Mine ( out of warranty) was cleaned and after that fine until the next desert trip. It has also happened a couple of times from the dust on the access road to my house. As you have pulled one apart any ideas? 2.7 D4 eDiff, Traxide Dual battery, Safari Snorkel...Opposite Lock winch bar..extra set 17" wheels with 245/70/17 BFG KM2 MTs..Warrior winch..Long range tank.
1982 2dr RRC renovated.
1983 Range Rover 2dr fitted with 300Tdi (with bigger turbo), 40mm body lift, Warn 9000i winch and BFG MT 265/75/16. Rear Maxidrive locker
1976 Landcruiser BJ40 with tipper body for the farm!!
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| 6th Jun 2010 1:06 am |
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AndrewW
Member Since: 06 Aug 2007
Location: Saddleworth
Posts: 2302
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I reckon I have.
The clutch mechanism design fails in two distinct ways, one of which will merely be a function of time and number of operations, the other to the amount of effort required to apply the brake. That's where maladjustment, sand, mud and ice take effect.
Forgive my acting like Hercule Poirot, but I'll give you the details when everyone is in the sitting room...
A 2006 D3 finally swapped for a 2016 D4 Graphite in Graphite grey. No mods
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| 6th Jun 2010 2:21 am |
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mrandmrsh
Member Since: 25 Sep 2008
Location: Holmfirth
Posts: 487
 
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Top work A - the BIG question is can it be modified to work reliably?
This could be the key to rishes beyond your wildest dreams (well maybe not that much). 2012 Defender 110 XS Utility 2.2
2012 D4 Commercial 255 8-speed, Active diff, lots of extras on order, comes Sept - ORDER CANCELLED (isn't divorce expensive....?)
2008/08 D3 HSE G4 - part exchanged for the 110
1987 110 CSW with 200 Tdi (now gone)
2007/57 D3 TDV6 HSE - NOW GONE owned 1/oct/08 to 31/dec/09
2007 Seat Altea Freetrack4 170 tdi (wife's car, wife now gone!)
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| 6th Jun 2010 8:53 am |
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AndrewW
Member Since: 06 Aug 2007
Location: Saddleworth
Posts: 2302
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That's the good news - one bronze bush made by a modelmaker (one of those 1:20 steam engine buffs) and one thrust washer.
Looking at making a "refurb pack". Resulting (simple) re-build will be much more reliable than OEM kit!! 
The struggle will be getting the EPB kit off** the vehicle to do it, and replacing. Weather seal will be a (meetable) challenge...
Off to a christening today, though 
More will follow.
A
**i.e. box, 2 brake cables and the emergency release cable - all need to come off, sadly 2006 D3 finally swapped for a 2016 D4 Graphite in Graphite grey. No mods
Last edited by AndrewW on 6th Jun 2010 8:36 pm. Edited 1 time in total
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| 6th Jun 2010 9:18 am |
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bambi
Member Since: 10 Apr 2009
Location: south yorkshire
Posts: 2059
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Well this is fab i love to see this good work you lot, i for one will look forward to the refurb kit and destuctions.
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| 6th Jun 2010 10:20 am |
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AndrewW
Member Since: 06 Aug 2007
Location: Saddleworth
Posts: 2302
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Whilst we are working this out - does anyone know their chips? as in 102-legged fast-blow fuse, or Integrated Circuit??
The main controller chip carries the serial no. / i.d
997-9900.1 21
TMS 980
471R1F138PZQ
CF-62A0YXW
© Ate 96
Does this mean anything to anybody???
A
PS Apart from the fact that the chip design is 14 years old and eight years older than the EPB concept??? - Can't be a bespoke device if it pre-dates the application... 2006 D3 finally swapped for a 2016 D4 Graphite in Graphite grey. No mods
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| 7th Jun 2010 11:51 pm |
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Trackman
Member Since: 16 Apr 2010
Location: Glasgow
Posts: 430
 
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Not had a lot of success with your chip.
None of the part numbers are recognised in any database I have access to, even TMS is not recognised which you would expect to be the manufacturer.
Normally when you find this it means its a re-badged device or a special made by some big semiconductor firm for someone in the commercial market .....  - more looking required!
Ian.
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| 8th Jun 2010 12:13 am |
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AndrewW
Member Since: 06 Aug 2007
Location: Saddleworth
Posts: 2302
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Thanks for trying!
Who/what is Ate? And IS it "designed in 1996"?? 2006 D3 finally swapped for a 2016 D4 Graphite in Graphite grey. No mods
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| 8th Jun 2010 4:03 am |
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NJSS
Member Since: 06 May 2009
Location: Catherington, Hampshire.
Posts: 10480
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This could be ATE:-
http://www.ate.de/generator/www/com/en/ate...09_en.html
they claim to be:-
Quote:the leading manufacturer in the field of brakes
NJSS Am I Gammon or Woke ? - I neither know nor care.
2016 Discovery 4 Landmark
2011 Mercedes Benz SL350 (R230)
1973 MG B GT V8 - 3.9L John Eales engine, 5 speed R380 gearbox, since 1975.
1959 MGA roadster - 1.9L Peter Burgess Engine - 5 speed gearbox
Past LRs - Multiple FFRs, Discos & a Series I - some petrol, some diesel,
none Electric or H2 fuel cell - yet.
There are 10 types of people in this world: Those who understand binary, and those who don’t.
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| 8th Jun 2010 7:14 am |
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SteveNorman
Member Since: 14 Oct 2005
Location: Somerset
Posts: 1144
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Ate / Teves are a well known German brake manufacturer, their parts are on virtually all cars.
Regards
Steve
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| 8th Jun 2010 7:37 am |
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Trackman
Member Since: 16 Apr 2010
Location: Glasgow
Posts: 430
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The name ATe and designed in 1996 is probably the firm who wrote the code that is in the device.
Its more than likely an FPGA which is like a Microcontroller and even if we found the generic part number it will not do us much good without the code!
Ian
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| 8th Jun 2010 10:40 am |
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green_discovery
Member Since: 03 May 2010
Location: Wiltshire
Posts: 11
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Very interesting AndrewW. I like most have had a screamer, the local garage opened up the EPB module and said it had swarf in it which was not good! They have ordered a new one but is on back order. Are the pictures viewable on this site?
I thought I could show them to the mechanic, I could get the parts made if the clutch is slipping in the unit.
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| 9th Jun 2010 11:26 pm |
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AndrewW
Member Since: 06 Aug 2007
Location: Saddleworth
Posts: 2302
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Hi, g_d!
It would be interesting to hear more of this "swarf" before you tell him the gearbox is a sealed unit (inside the sealed EPB unit) and the gears are all plastic...
Explanatory text and incriminating pictures are on their way. Apologies, but I am arranging a funeral for a close friend Thurs/Friday and away all weekend That hasn't prevented work on it, but slowed it down ++.
Andy 2006 D3 finally swapped for a 2016 D4 Graphite in Graphite grey. No mods
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| 10th Jun 2010 12:33 am |
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