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Big Brake kit.

Let me know if you have any questions.

Braking performance in our heavily loaded expedition tourer is substantially improved ( no surprise ) over the OEM front / rear braking setup.

It’s also easier to find front / rear pads for this setup - I’ve noted the relevant part numbers within my build thread.
 
Towing a ~6500lb trailer (with new good quality trailer brakes) from Ouray Colorado to Durango Colorado really changed my mind on the Grenadier's brakes (at least with the petrol engine and its poor engine braking). Despite me going much slower than the speed limit, not riding the brakes, keeping engine braking at ~5,000 rpm, and making sure the trailer brakes were carrying their share of the load, the brake fade was so bad that I had to take multiple breaks to let the brakes cool. The last time I pulled into a stop it took me about 200 meters to stop from 35 mph and most of that braking came from the trailer.

I have the Agile Big Brake Kit installed now but haven't actually towed with them yet. Around town though, they just feel so much more responsive. Better braking with faster response and better pedal feel.

The two piston front brakes and one piston rear are just not adequate for the towing loads the Grenadier is rated at. Sadly, it is only a matter of time until someone learns this the hard way.


EDIT - All that being said, I wish someone would create a brake kit for the rear axle that maintains use of the handbrake.
You know it’s bad when you have to take brake breaks.
I haven’t towed heavy loads but have noticed the diesel engine braking is great.
Also the ability to use low range on hard surfaces up to 80 kmh/50 mph is also great
 
The factory brakes seem more than good enough until you really have to push that pedal, as in sh1t I've really got to hard brake - there doesn't seem to be any more stopping power however hard you push the pedal. Probably not describing it too well but if you need to make a close to emergency braking then the bite of the brakes does not seem to intensify. Yes it's a heavy old truck but I would expect some better performance when in brown trouser mode. I wouldn't go as far as saying brake fade but would certainly like a bit more feel and power.
 
I think you describe it well @ECrider , you push the brake hard and your almost down to the metal, pumping twice for posterity but still it doesn't feel like the brakes are biting. That's the feeling. Only prevalent when the vehicle is heavy or you're towing + very steep inclines (20% or more).

I also worry about emergency braking, will the pistons bite hard enough?
 
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Just adding a few observations following two fairly recent overlanding trips:

The 1st was 5 days driving up/down the Italian & Swiss Alps on rough & steep offroad trails in June (plus driving motorways to/from London) and the 2nd was spent covering about 1,000 miles overlanding through Morocco on everything from flat sandy/gravel plains to come steeper technical ascents/descents (plus c.4,500 miles motorway to/from London). On the first trip I estimate that the total vehicle weight + myself was around 3.3 tonnes, and across Morocco we found a weigh-bridge which confirmed that we were running at 3.65 tonnes incl. 2 people.

During the trip in the Alps I did a number of long steep descents that brought me down 1,000-1,500 meters in the course of 30-45 minutes, and the brakes were absolutely roasting. I was using a combination of the built in hill descent mode plus foot brake on the less steep sections. I didn't have any noticeable brake fade, but the stench of hot brake pads was impossible to ignore. From what I've read about the Powerbrake X-line kit, the larger discs and increased disc ventilation their should help reduce heat build-up and improve subsequent cooling of the system.

In Morocco, there were a few occasions when I had to brake firmly when wayward cars/pedestrians/animals stepped onto the road, or cars in front did something unexpected, and in most instances I felt that the vehicle's weight was overtaking the brakes. On these occasions the brakes were not running hot - it was simply a matter of mass vs resistance. I feel that the Powerbrakes larger disc diameter will give me greater leverage, and the 6-pot calipers will give be greater braking force.

Much of the analysis in this thread looks at trailer braking. Does anyone have lived examples similar to mine, where the change to a big brake kit brought benefits as I'm expecting above? Noting that the kit plus fitment will not leave much change from £5,000, I want to get this right (alongside general peace of mind!).
 
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I think I'm going to get the power brake system . I think anyone with a heavier vehicle or towing should consider a brake upgrade. Is was in very steep terrain today and it was a bit sketchy with the factory brake IMHO.

Just adding a few observations following two fairly recent overlanding trips:

The 1st was 5 days driving up/down the Italian & Swiss Alps on rough & steep offroad trails in June (plus driving motorways to/from London) and the 2nd was spent covering about 1,000 miles overlanding through Morocco on everything from flat sandy/gravel plains to come steeper technical ascents/descents (plus c.4,500 miles motorway to/from London). On the first trip I estimate that the total vehicle weight + myself was around 3.3 tonnes, and across Morocco we found a weigh-bridge which confirmed that we were running at 3.65 tonnes incl. 2 people.

During the trip in the Alps I did a number of long steep descents that brought me down 1,000-1,500 meters in the course of 30-45 minutes, and the brakes were absolutely roasting. I was using a combination of the built in hill descent mode plus foot brake on the less steep sections. I didn't have any noticeable brake fade, but the stench of hot brake pads was impossible to ignore. From what I've read about the Powerbrake X-line kit, the larger discs and increased disc ventilation their should help reduce heat build-up and improve subsequent cooling of the system.

In Morocco, there were a few occasions when I had to brake firmly when wayward cars/pedestrians/animals stepped onto the road, or cars in front did something unexpected, and in most instances I felt that the vehicle's weight was overtaking the brakes. On these occasions the brakes were not running hot - it was simply a matter of mass vs resistance. I feel that the Powerbrakes larger disc diameter will give me greater leverage, and the 6-pot calipers will give be greater braking force.

Much of the analysis in this thread looks at trailer braking. Does anyone have lived examples similar to mine, where the change to a big brake kit brought benefits as I'm expecting above? Noting that the kit plus fitment will not leave much change from £5,000, I want to get this right (alongside general peace of mind!).
You won’t regret getting the PowerBrake X-line kit! It’s a very simple and reliable upgrade to performance and maintenance intervals will extend as well.

The other options: Buzz and Alcon/Agile are fantastic as well.

Folks are often replacing seals as well on the OE calipers due to heat issues
 
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Just adding a few observations following two fairly recent overlanding trips:

The 1st was 5 days driving up/down the Italian & Swiss Alps on rough & steep offroad trails in June (plus driving motorways to/from London) and the 2nd was spent covering about 1,000 miles overlanding through Morocco on everything from flat sandy/gravel plains to come steeper technical ascents/descents (plus c.4,500 miles motorway to/from London). On the first trip I estimate that the total vehicle weight + myself was around 3.3 tonnes, and across Morocco we found a weigh-bridge which confirmed that we were running at 3.65 tonnes incl. 2 people.

During the trip in the Alps I did a number of long steep descents that brought me down 1,000-1,500 meters in the course of 30-45 minutes, and the brakes were absolutely roasting. I was using a combination of the built in hill descent mode plus foot brake on the less steep sections. I didn't have any noticeable brake fade, but the stench of hot brake pads was impossible to ignore. From what I've read about the Powerbrake X-line kit, the larger discs and increased disc ventilation their should help reduce heat build-up and improve subsequent cooling of the system.

In Morocco, there were a few occasions when I had to brake firmly when wayward cars/pedestrians/animals stepped onto the road, or cars in front did something unexpected, and in most instances I felt that the vehicle's weight was overtaking the brakes. On these occasions the brakes were not running hot - it was simply a matter of mass vs resistance. I feel that the Powerbrakes larger disc diameter will give me greater leverage, and the 6-pot calipers will give be greater braking force.

Much of the analysis in this thread looks at trailer braking. Does anyone have lived examples similar to mine, where the change to a big brake kit brought benefits as I'm expecting above? Noting that the kit plus fitment will not leave much change from £5,000, I want to get this right (alongside general peace of mind!).

I'm sure everyone who has fitted either the Alcon/Agile or Powerbrake x-line kit will say how much better and stronger the brakes are. It's the seat-to-pants instrument that has a built-in J curve for higher spends.

Naturally if you increase the rotor diameter and the pad surface area in contact you should expect an improvement in the braking effect. Improve the heat dissipation to keep everything within spec and it should be a winner. Take my money.

But like Alcon/Agile, Powerbrake don't appear to quantify their improvements via actual performance data. For the asking price I would want to see at least a comparison of deceleration and stopping distance tests to prove their claims. For towing I would also want to see repeat hot stopping test data to see the reduction in brake fade. This is not unreasonable to expect and it's where your money matters, right?

If the vehicle brakes are being overwhelmed because of a coupled trailer (>750kg) the trailer brakes are not doing their job. I would be addressing that before throwing money at better vehicle brakes, especially if you're happy with the vehicle brakes when not towing. You may still end up doing a BBK upgrade but improving your trailer brakes is never a bad investment.

Or, forget all that. Get the upgrade and hope for the best. Go for the red calipers. Red stops faster ;)

------------

I posted earlier about the need for effective trailer brakes. Again:

- Vehicle brakes are responsible for the vehicle up to the maximum loaded weight and have sufficient reserve capacity for an unbraked trailer up to an approved amount. I think it's 750kg trailer GVW in the UK.

- Trailer brakes are responsible for all additional braking effort at combination weights above vehicle + unbraked trailer at GVWs.

I tow a 2 tonne camper with 10" Dexter style electric drum brakes operated by a Bendix brake controller (same functions as the Redarc TowPro Elite at about 40% of the Redarc price). Two tonnes is not particularly heavy and well under the towing limit of the Grenadier.
I press the manual override button to test the trailer brakes after every set off so I know they're operating.
I increase the brake controller dial setting at higher speeds so the trailer brakes produce more stopping power. The inertia/proportional control mode reacts to how hard you brake not how heavy you are, but inertia increases with mass so there is some crossover at higher speeds and weights.
I decrease the controller setting when off-road so the trailer wheels are less likely to lock up (no ABS).
I use the manual override button to brake the trailer first on slippery downhill slopes to help keep the trailer behind me.
 
FWIW I’m noticing a decrease in stopping distance and brake fade has been eliminated while driving to and from Mt. Hood in winter and across various forest roads through Timberline etc. Our vehicle is roughly ~6800 Lbs ( ~3100 Kgs ) fully loaded.
 
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my car is 7,100 loaded. not so much of an issue normally to stop but emergency stops and hard braking going down a hill, particularly offroad is a bit sketchy - i certainly think i would benefit from better clamping force and modulation. i compared my heavy car with a stock car and its quite the difference in brake feel between them.
 
i don't know about that guy. isn't the whole idea of bigger brakes to have better thermal management so you can use more agressive pads? i just assumed this is what greater pedal feel came from, i didn't think for a second that come from the pistons or the disc but from the new pad compound that is now available to you since you can up the thermals quite a bit. or am i misunderstanding this? I can't say this is my true skill (electronics is where i live my life).

I just assumed that was what was the big deal with these kits. and yes, i would love some more scientific data on it.

the the whole point about front and rear brakes and that you mess with the system seemed off to me. It sounded like he was assuming no braking proportioning valve, but then the pressure is equal in the system as a whole. With an old school brake proportioning valve maybe he is right ?

But i thought ineos used their tire rotation sensors to control the proportioning valve and the ABS circuit on a per tire or on a per brake circuit basis. I assumed at least that is how its implemented or how else would the abs know if a pair of wheels a locking up?

other than that i tend to agree. there is a point to be made about smaller cylinders vs larger cylinders and cylinder count vs flex -but i'm not experienced enough to have a well formed opinion.
 
My interpretation is that big brakes kits make no difference in minimum stopping distance assuming the original brakes are capable of locking up the wheels. Obviously the OE brakes on the Grenadier can do this (limited by the ABS system of course). However, what we are interested in is heat management, modulation and feel and this is where big brake kits can make a real difference because of the greater mass, larger diameter rotors and increased pad area.
 
i dont really know. i do know that a bigger piston area requires more pedal travel to create the same clamping force which is what many call better modulation. i think that in combination with better thermal management should create a more precise control.
 
The part that is left out of most kits is a replacement master cylinder matched to the fluid volume and piston count of the replacement calipers. Pairing the new calipers with an optimal master cylinder will produce the best feel/modulation together with sweet spot pedal pressure. This is typical for big brake kits in Jeeps but it seems uncommon for most other vehicles that are not being built for racing.
 
Bigger brake pads dissipate heat better but changes nothing regarding the breaking force. To have more breaking force you need more pressure or a different surface. More pressure comes through a changed piston desing in the brakes.

AWo
 
Powerbrake, who manufacture and sell BBKs so have a different interest, have a bit to say about the expected benefits of a BBK on their global website. A more accurate description would be Heavy Duty Brake Kit but Big Brake Kit sounds better.


Screenshot_20251209-175625.png

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Independent testing of Powerbrakes

View: https://youtu.be/xuvx63J9Mv4?si=s-lT3aMM11clw4Op


View: https://youtu.be/u-3TKrFe6NE?si=bKL76YeSTNv3cFJl

A comment under the second video calls out one of the main points to remember, which I find relevant to my reason for considering this change:


@IssaqAl-Ahmed

1 year ago
Worth mentioning that big brake kits will not provide stopping distance improvements if your current braking system isn't overloaded. On a non-overloaded vehicle, stopping distance usually improves most with and increase in tire contact patch . Generally speaking, if you just threw these on to a stock vehicle you likely wouldn't see anywhere near as big of a stopping distance difference improvement. Not all vehicles are equal, but generally that should be the case. +1 the closing comment about brake fade, big brake kits 100% should help there over stock. More thermal mass and usually better venting.
 
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