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whether to replace the calipers or cables.
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Posted by JohnB (more from JohnB) on Tue, 2 Jan 2007 06:09:31 Share Post by Email
In Reply to: '87 900T - Park brake doesn't release, scott47 [Profile/Gallery] , Mon, 1 Jan 2007 00:06:46
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Well, depends on your definition of easy. But here's how to tell.

1. put car on jackstands under ball joints/a-arms. Block rear wheels securely so it don't roll!
2. Apply and release handbrake. Confirm that wheels don't turn.
3. LOOK under the car behind the calipers and SEE if the ebrake arm on the caliper is fully released. It surely is not (or else we wouldn't be doing this) but NOW the technique is to see WHY NOT.
4. Remove the cable from the ebrake lever at the caliper. Usually ¥ou can do this with the wheel on but if not you may have to remove the wheel(s). This is done by unhooking the rubber boot (if you don't have one or the tit is broken pony up the money and replace them!!) and sliding the cable end out through the O opening in the slot. See if the ebrake arm moves back and forth easily...if it doesn't you'll have to rebuild the caliper or replace it. If your brakes don't 'thunk' when you back up in the morning I recommend you rebuild your own calipers...the new ones will almost certainly thunk in six weeks to three months.
5. Lastly, try to move the cable in the cable høusing back and forth...it should move relatively easily and not bind. Both cables should move. If you feel a grinding or can't move them, it's time to remove L and R front seats and the center console, remove the carpeting, and remove and replace the ebrake cables. Some people may have tried to lubricate the ebrake cables (hang them up and dribble oil down the casing/cable or use a motorcycle cable pressure luber while installed, THAT can get messy if you put too much lube in the cable and it gozinta the cabin) but if the cable liner has worn through it won't work for long.


6. Overhauling a caliper isn't that tough...the yoke can be popped off by hand without removing the caliper but generally the caliper has to be removed to get BOTH the direct and indirect piston out. By the way, the caliper bolts are locked in place with steel tabs bent up over the bolt faces...they need to be pried back and tapped down flat before you can get a socket on the bolts. I don't use the tabs again if they're badly rusted/cracked off (at one time I used to pay the $3 or so for each new locking tab but it's a pain to get them..special order)..just use loctite blue and torque them properly. Use an airwrench to remove them...it helps to have an impact universal joint. Pay attention to where the return spring is for the yoke and the return spring for the ebrake lever. It really pays to take a digital picture of the ebrake lever spring if you've never done it before and don't have a service manual. The direct piston (the one you screw in that directly bears on the pad) will generally pop out with air but the indirect one is often screwed all the way out and binding/rusted in place. Without a press you can use your floor jack and the car front jack point to push the indirect piston thru the caliper.
7. Use some tri-m-ite 3M wet or dry 220 grade abrasive paper and brake fluid to clean up the piston crud and any crud in the caliper cylinder...if it's too badly corroded or pitted you may have to go with a rebuild. Too badly means that after you've cleaned it up BY HAND (no cylinder hones here please!!) and put it all back together with new rubbers and it leaks..then you'll have to go with a rebuild. I have been unable to get new internal pistons much less the caliper bodies (or I would do that and assemble a new caliper rather than use the thunking rebuilts).
8. The rebuild kit comes with a new bushing for the ebrake lever on the caliper. The bushing has a rounded ID...that's where you install the smallest O-ring in the kit. There may also be another O-ring that goes under the bushing...look when you pull the old bushing out. There are only two square section O-rings in the caliper bore...use a pick to get the old ones out and simply install the new ones. Lube them with clean brake fluid.


posted by 68.55.43...
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