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Handbrake Woes!

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Old Mar 9th, 2011, 18:13   #41
Ex 850/V70 Register Keepe

Last Online: Jan 13th, 2019 17:22
Join Date: May 2006
Location: Eltham, London

I ordered up all the parts and they arrived today.
Attached has all the part numbers and FRF Prices from Rufe.
Ignore Line 4 "Dipstick" you don't need a new dipstick for the rear brakes.
Attached Images
File Type: jpg S80 Brakes parts.jpg (176.2 KB, 93 views)
66,145,264 GLE,265 GLE (2 off),765 GLE,740 GL Estate, G 760 GLE Estate, N 960 CDi, W 940 SE,'51 V70 T,'56 V70 T5. '57 G3 V70 D5 '10 V70 T6 AWD Polestar (Bye Bye), Wife's '03 S80 SE I like Volvos.
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Old Mar 12th, 2011, 20:14   #42
Ex 850/V70 Register Keepe

Last Online: Jan 13th, 2019 17:22
Join Date: May 2006
Location: Eltham, London
Default How to do it

All pictures from the driver side.
You will need Loctite, Copperslip, and Brake cleaner.
First check you parts list. Pic 0.
Snap off the handbrake lever cover to expose handbrake cable adjuster. Pic 1
Slaken (all the way) off the handbrake cable. Long series 10mm socket. Pic 2
Put car in Park or First gear and chock front wheels. Remove road wheel and support car on axle stands. Pic 3
Locate the rubber covers and plastic cap that conceals the caliper bolts, remove the cap and keep it to one side. Pic 4
Unclip the ABS wire and move it out of harms way.
Pull the caliper assembly towards you to push back the slave cylinder, or use a flat screwdriver between the pads and the disc to prise the cylinder back. You are going to throw away the disc and pads so no harm done. Spring off the outer retaining clip
Using a Hex 7mm undo the caliper bolts. Pic 5
Support the removed caliper so as not to strain the brake pipes with an old coat hanger. Pic 6
Remove the caliper carrier. 14 mm ratchet ring spanner. Pic 7, Pic 8.
Pull the disc towards you and remove. Pic 9
Detail pics of rear and forward views of shoe seats and spring layout Pic 10, Pic 11.
Remove the shoe retaining springs by cutting them off with a pair of wire cutters. Always fit new springs, Lift off the shoes, start with the non handbrake actuator side.( right hand)
This is what you now have Pic 12
Detail of shoe retaining spring mount Pic 13
Clean everything! Pic 14 And have a cup 'o tea.
This is how the assembly will look when assembled on the backplate . Pic A
Small dob of copperslip on all the shoe bearing points.
Refit the top shoe first.
The shoe retaining spring is easily fitted with a pair of snipe nose pliers, grip the centre of the spring, push in and sideways. When it goes in properly you get a very satisfying "snap/click". Check you got it right! Important Pic 15
Fit the spacer bar and small spring with the lower shoe loose, (RH side)
then swing the lower shoe up into place and refit the lower shoe retaining spring.
Seat the LH sides onto the handbrake actuator mechanism, and refit the larger spring. Easiest to hook the spring onto the top shoe, grab the bottom of the spring with a pair of snipe nose pliers, and stretch it down to the lower shoe. Mind you don't get a face full of spring, this is not easy!
It should now look like this, Pic 16
Fit the new disc. Pic 17
Refit the caplier carrier, use Locktite on the bolt threads.
Unhook the caliper, clean, and put a small amount of Copperslip in the pad seating groves. Fit the new inboard pad first, peel the backing from the outboard pad and fit the pads and caliper together onto the disc/carrier. Refit the carrier bolts and replace the plastic caps Pic 18.
Refit the outer retaining clip.
Refit the road wheel.
Gently press the brake pedal until you get "feel" back, to seat the new pads.

Now you must do the other side.

When the other side is completed return to the handbrake cable adjuster in the cabin. Before tightening up the adjuster nut, pull the handbrake up until it just bites and rotate each road wheel to centre up the shoes.
Finally adjust the handbrake cable until you have 3 clicks to fully on.

Carefully road test the car. Full rear braking will take a few (30-40)miles to bed in so dont just go stamping on the brakes and be aware of a slightly longer stopping distance until it all beds in.
Simplees! Enjoy.
Attached Images
File Type: jpg 0 Get the parts.jpg (231.9 KB, 167 views)
File Type: jpg 1 start here.jpg (173.6 KB, 176 views)
File Type: jpg 2 slaken handbrake cable.jpg (211.5 KB, 164 views)
File Type: jpg 3 before we start.jpg (171.3 KB, 170 views)
File Type: jpg 4 locate rubber cap on cliper bolts.jpg (162.2 KB, 162 views)
File Type: jpg 5 Remove Caliper bolts.jpg (208.9 KB, 165 views)
File Type: jpg 6 hang up caliper with a coat hanger.jpg (195.8 KB, 155 views)
File Type: jpg 7 Remove Caliper Carrier assembly.jpg (182.0 KB, 159 views)
File Type: jpg 8 This is what it looks like.jpg (194.2 KB, 172 views)
File Type: jpg 9 Disc off.jpg (196.8 KB, 162 views)
File Type: jpg 10 Handbrake actuator detail.jpg (239.7 KB, 254 views)
File Type: jpg 11 other side.jpg (193.9 KB, 166 views)
File Type: jpg 12 Shoes off handbrake actuator.jpg (231.4 KB, 180 views)
File Type: jpg 13 shoe retaing spring mount.jpg (235.4 KB, 168 views)
File Type: jpg 14 All clean and ready for new parts.jpg (174.9 KB, 175 views)
File Type: jpg A shoe assembley showing sping locations.jpg (223.9 KB, 172 views)
File Type: jpg 15 How to refit the shoe retaining springs.jpg (210.3 KB, 178 views)
File Type: jpg 16 New shoe components in place.jpg (264.4 KB, 174 views)
File Type: jpg 17 Hold new disc in place with a couple of whhel bolts.jpg (272.1 KB, 162 views)
File Type: jpg 18 All done bar the retaining clip.jpg (251.8 KB, 159 views)
66,145,264 GLE,265 GLE (2 off),765 GLE,740 GL Estate, G 760 GLE Estate, N 960 CDi, W 940 SE,'51 V70 T,'56 V70 T5. '57 G3 V70 D5 '10 V70 T6 AWD Polestar (Bye Bye), Wife's '03 S80 SE I like Volvos.
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