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Caliper Overhaul

#1 User is offline   eldoodarino 

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Posted 21 April 2010 - 05:21 PM

I Recently overhauled a set of standard calipers...

just thought i'd post a few piccies of what needs to be done to restore the front brakes too 100% again... :good:

Firstly, strip down ALL parts... remove the black caps off the back of each caliper and undo the allen bolts with a 7mm key... if you have standard hoses fitted still (which are a real pain in the ARSE!) you'll notice you can't unscrew the pipe as it has no swivel union.. :blink: so you then have to unscrew the caliper from the hose... lol...this is complicated by the fact that the hose is actually in the way of getting to the allen bolt!.... :rant: :comp: :guns: Halfords sell a long reach 7mm brake tool which solves this little dillema out.... i managed to snap one of my 'bits' and had to piece 'bits' together which would reach in but it was stupidly awkward....

If you change the brake pipe (recommended) to an Apec one, you won't ever have this stupid issue, as you can just unscrew the pipe without any hassle....(see later piccy).. :bleh:

Posted Image

ideally, then shotblast the castings down.... i used an aluminium oxide 60 grit... the caliper should be fairly straight forward to clean up, but you may find the mounting arm is SERIOUSLY crusted up with dirt and rust.... took me ages to get it back to this state... :head:

Posted Image

Then paint the calipers....

I used a 2k Acrylic spray finish here....mounting the arms on an M10 bolt on a long piece of wood....the calipers i do in 2 halfs, which is time consuming.. :angry:

Posted Image

Bolt it all back to the car.... :woot2: :woot2:

Posted Image

any more info needed just ask...

:cool:

Chris
frp453
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#2 User is offline   FlashBastd 

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Posted 21 April 2010 - 05:41 PM

Those look like ST170 brakes!
2005 Vauxhall VX220 Turbo
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#3 User is offline   eldoodarino 

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Posted 21 April 2010 - 06:04 PM

They're quite big aren't they... :lol:

on an early puma so the drums look real small in comparison.. they certainly snap necks tho.. :D
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#4 User is offline   ScubaSteve 

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Posted 21 April 2010 - 08:19 PM

can you get shorter APEC brake pipes? you know why i ask hahaha

#5 User is offline   FlashBastd 

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Posted 21 April 2010 - 08:49 PM

So you have fitted those to a car with an early servo and master cylinder? I take it there isn't much dead travel before they bite?

Nice guide too btw!
2005 Vauxhall VX220 Turbo
2000 Ford Focus 1.6i Ghia
2006 Renault Clio 2.0i RenaultSport 197 - SOLD
2005 Honda CR-V 2.0i Executive auto
2001 Ford Puma 1.7i Black

#6 User is offline   eldoodarino 

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Posted 21 April 2010 - 08:54 PM

Pumaspeed fitted them a while ago now... i just cleaned them up...

The pedal seems very firm to me...

Quote

can you get shorter APEC brake pipes? you know why i ask hahaha


:lol: i'd have to go there and open a few boxes i guess.... so...don't know is the answer... :P
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#7 User is offline   AndyW 

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Posted 22 April 2010 - 03:20 PM

These are the ST150 brakes :P

And yes, they do snap necks as Chris well knows B)
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#8 User is offline   FlashBastd 

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Posted 22 April 2010 - 03:38 PM

Ah, ST170's in all but the carriers!
2005 Vauxhall VX220 Turbo
2000 Ford Focus 1.6i Ghia
2006 Renault Clio 2.0i RenaultSport 197 - SOLD
2005 Honda CR-V 2.0i Executive auto
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#9 User is offline   mikecat 

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Posted 25 April 2010 - 12:41 AM

do you do a service on frp rear calipers chris?

#10 User is offline   eldoodarino 

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Posted 25 April 2010 - 09:38 PM

I havn't done in the past...but certainly well worth taking them off every couple of years, as they can get VERY rusty and seized up....

i keep the pads and discs in stock usually, but don't offer the 'swap out' service like the Alcons...

:good:

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#11 User is offline   mikecat 

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Posted 26 April 2010 - 09:08 AM

yeah one side of mine is seized, and the other side, the pads only seem to touch be touching the last the cm of brake disc.

Looks like you could have a big job on your hands in july, and i need to get some serious saving going on, lol.

#12 User is offline   eldoodarino 

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Posted 26 April 2010 - 10:21 AM

View Postmikecat, on 26 April 2010 - 09:08 AM, said:

the pads only seem to touch be touching the last the cm of brake disc.


that sounds like the caliper mounting arm is knackered, or someone has threaded the bolt in 'wonky'.. i'll dig out the part number for that... the arm is around 60-70 squid i think

is it defo the piston is stuck, or the handbrake cable...? :huh:

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#13 User is offline   mikecat 

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Posted 26 April 2010 - 10:34 AM

on the one side it seems to be the caliper sticking. in your pic you have them seperated, when i had them off i couldnt seperate one side, it seemed really jammed! When on the car it feels like that side isnt even braking an doesnt show much wear on the new disc thats on.

The other side i manged to seperate, did move freely but when on the car there is only wear on the very edge. Dont think the piston is sticking, seemed to pop back in ok. Maybe it is the handbrake rubbing!

So when are you free in july???? lol

#14 User is offline   eldoodarino 

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Posted 26 April 2010 - 12:20 PM

Pumabuild have all the handbrake cables..lol ...

maybe worth getting one....

can't really diagnose it till i see it... mid may or early july is good.. :good:
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#15 User is offline   m3galon 

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Posted 27 April 2010 - 08:13 PM

Hi Chris

I'm just upgrading my 240's to 270's at the moment, I've overhaul the calipers, replaced the pistons, seals and boot kit; only I'm now stuck fitting the pads...

I can't get the pad retaining clip back on, is there some dark art or nak to this?! :blink:

Any help or advice would be appreciated!

Thanks
Karen

#16 User is offline   eldoodarino 

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Posted 27 April 2010 - 08:54 PM

doh!..stumped at the last hurdle.. :lol:

put one end on by hand... the other side is awkward..you have to grab the end with a pair of pliers and force it over into the groove..

:D
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#17 User is offline   m3galon 

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Posted 27 April 2010 - 09:20 PM

View Posteldoodarino, on 27 April 2010 - 08:54 PM, said:

doh!..stumped at the last hurdle.. :lol:

put one end on by hand... the other side is awkward..you have to grab the end with a pair of pliers and force it over into the groove..

:D


:blush: I was pretty much doing that, but at least now I know it's not meant to be easy. I'll get a bigger pair of pliers on them tomorrow.

Thanks for the quick response! :cool:

#18 User is offline   WezzyG 

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Posted 29 August 2010 - 05:23 PM

coolio

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