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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 ďlocked 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 donít 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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Old 06-08-2023, 02:36 PM   #9
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Quote:
Originally Posted by vito.a View Post
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.


Hi Vito,
Now 3 1/2 years later and 10,000 miles, Iím facing the same shot rotor, caliper, and pad scenario as in 2019. Hard to believe this is possible. I keep my coach here in AZ now so it is at EAST VALLEY RV SPECIALISTS in Apache Junction. No one seems to have a good theory as to whatís causing this problem. Any thoughts?
Your above thoughts donít seem to lead to an answer.
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Old 06-08-2023, 02:39 PM   #10
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Quote:
Originally Posted by DuaneHuff View Post
Hi Vito,
Now 3 1/2 years later and 10,000 miles, Iím facing the same shot rotor, caliper, and pad scenario as in 2019. Hard to believe this is possible. I keep my coach here in AZ now so it is at EAST VALLEY RV SPECIALISTS in Apache Junction. No one seems to have a good theory as to whatís causing this problem. Any thoughts?
Your above thoughts donít seem to lead to an answer.


Also, as a driver, the brakes are at the forefront of my mind. I use the jake, and moderate speeds. Never ďrideĒ the brakes!
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Old 06-08-2023, 04:24 PM   #11
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Does the adjuster turn easy when you put a socket on it? Bendix uses a chain I think to drive both sides of the adjuster, haldex uses gears( may have it backwards) in any case the gasket around the air actuator can leak water into the adjuster and locks them up. There is a shear value on the adjuster that will break if twisted to hard while adjusting them. Don't blame yourself or your mechanic if the adjuster is froze and that little deal breaks. They are cheap. Next is take a close look at your spindle. It could be grooved on one side bottom being the most common, where one of the bearing races sits and allows the wheel to wobble slightly or tilt slightly. The haldex caliper assembly is / was 1200, the bendix was 3200. Monaco used haldex as far as i have seen. There is a company in china making just the adjuster for 50$ but they wanted to sell me 50 or 100 of them.

https://www.finditparts.com/products...iABEgIRXPD_BwE

There's the little shear adapter

Other than the chain drive the haldex is the same for practical purposes

https://cumberland-companies.com/wp-...ake-Manual.pdf
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Old 06-08-2023, 05:43 PM   #12
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Thanks for the input! My Monaco used Meritor brake parts. I assume they are Meritor brakes.
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Old 06-08-2023, 05:45 PM   #13
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Quote:
Originally Posted by DuaneHuff View Post
Thanks for the input! My Monaco used Meritor brake parts. I assume they are Meritor brakes.
Meritor makes the same caliper as well, pads are all interchangeable
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Old 06-08-2023, 07:10 PM   #14
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Quote:
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Meritor makes the same caliper as well, pads are all interchangeable


Thank you! Good to know.
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