The never ending brake saga !!

[VMH]

Are the front brake pistons greased or oiled? If they are the pistons can travel too far back into the calipers causing this problem. Pump the pistons out as far as possible without them coming out completely and clean with petrol or brake cleaner.
To be fair I have never come across this problem on vans, only motorbikes. Probably because no one greases the pistons on vans.

[cherniy_chack]

Large gaps in the front brakes are possible with the wear of the guide rods of the supports. This leads to a wedge-shaped wear of the front brake pads.
If you notice the wedge wear of the pads, you need to repair the guides.
When removing air motor can not start, when checking the brakes, you need to start.

[fuzzedup]

Hi all, thanks for all the advice. It turned out to be a dodgy calliper even though they were both brand new. Chased the problem by clamping front hoses off and ended up with the drivers side as the culprit. Replaced the caliper and all good and my van now has a full MOT with only one advisory (offside drivers wing had corrosion). Well chuffed that all them days slogging it out in the wet and wind has paid off
Paul

[dumper]

Glad you got it sorted it’s allways a sickening when you find out a new part is defective I you think it impossible that it’s the culprit and go changing more parts that have no fault on the

[cherniy_chack]

It's nice to know that the problem is solved.
Let the solution was not where I indicated it.
Who could have known that the new part would be bad?
A large free brake pedal travel is always indicative of large gaps in the working brakes.

[Chug]

Good to hear you have found the problem and are back on the road,
it's a headache when new parts are defective but are ruled out of the problem due to being new.