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Old 09-17-2019, 12:03 PM   #1
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2002 Monaco Signature brake problems

I have owned this coach for ten years without brake problems until a couple of years ago. At 78,000 miles I had metal to metal contact on the drivers side drive wheel disc brake. It was determined that the caliper had “locked up and destroyed the rotor, requiring replacement of rotor, caliper and pads. 17,000 miles later, same scenario. Anyone have similar experience?
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Old 09-17-2019, 07:07 PM   #2
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Not on a motorhome but a common cause of this type of problem is the shorter flexible hose that connects to the caliper. The internal lining breaks down and blocks the brake fluid from returning causing the brake pad to stay in contact with the rotor. This happened on my wifes Chrysler van, the mechanic we use knew exactly what it was.
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Old 09-17-2019, 08:30 PM   #3
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Hi DuaneHuff; I do not have air disk brakes on my 01 Windsor so I don't have any experience with the problem you are having, but a number of years ago I was thinking of buying an 03 H.R. Imperial and it had air disk brakes up front. For some reason I was doing research on those brakes, think this was in 2015 so a while ago, and I remember reading about the lubing process to keep the parts in the air disk brake from seizing up do to lack of operation. I know this is no help as I can't remember where I read this information. I am just guessing here as I wonder how much you coach is driven in a certain time period and weather corrosion is building up somewhere and causing the caliper not to release. As Jim mentioned lack of use or parts that go bad over a period of time. Just my thoughts and don't know if this info helps you any.
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Old 09-19-2019, 10:15 AM   #4
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Hi ! Welcome to IRV2! We're sure glad you joined the gang!

I haven't had that problem with our 2002 Windsor so don't have suggestions. Noticed you are new on IRV2 and wanted to say hello!

Good luck, happy trails, and God bless!
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Old 09-19-2019, 03:46 PM   #5
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I'm interested in your issue but do not have any easy answers.
Usually a repeat failure shortly after a repair is caused because the repair was not performed correctly.

I assume you use your engine Jake brake regularly to preserve and not overheat the service brakes?
Air disc brakes are becoming more popular on heavy class 8 trucks because of new federal regulations. Unlike a car, heavy truck air brakes operate in reverse. They are locked until you apply air pressure to unlock them.
Does your air system maintain at least 85psi?
Do you drain the water drains on your air tanks regularly?
You should have drains on both the front and rear.
Have you maintained and changed the desiccant filter on your air dryer?
Water in the system can corrode components and freeze causing issues.

We have some very experienced heavy vehicle maintenance folks on here. I'll send them a PM and ask that they look at your post.
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Old 09-20-2019, 10:48 AM   #6
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I think it is going to be a caliper "not sliding" issue - either due to improper assembly/lubing, or worn slide pins.

I think you would have the Bendix ESD225 disc brakes (same as my coach).
When a pad replacement is done, one can "just replace the pads", or get the full pad "overhaul kit" which has the pads, boots, and slide pins.

Maybe the last brake job done just "reused the pins and boots" and now your paying for it.

When the wheel is removed, and the pads pulled out, you should be able to slide the caliper assembly back and forth on the slide pins with little effort.
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Old 09-21-2019, 06:07 PM   #7
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Although I don’t have a Monaco, I have not been diligent at draining off the air tanks with the pull cord. The logic of excess moisture in the air creating rust and corrosion seems very plausible in causing the brake calipers to stick closed.
I am going to be more vigilant.....
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Old 09-22-2019, 09:17 AM   #8
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Not that's a bad idea to be vigilant keeping the air tanks dry, but the same problems with worn pins and guides, bad boots. no brake lube , causing excess wear and lesser performance. Same thing happens on hydraulic brakes in a car. years 2000s autos , have pad retainers/slides now too that need to be replaced mostly every time.
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