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PV, 120 (Amazon), 1800 General Forum for the Volvo PV, 120 and 1800 cars |
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Brake Caliper RebuildViews : 5913 Replies : 27Users Viewing This Thread : |
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May 16th, 2014, 16:28 | #1 |
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Brake Caliper Rebuild
If anyone is mad enough to rebuild your own front brake calipers instead of spending the £97 on a reconditioned one, here's how:
This is quite something: on a 3 pot caliper, the inside piston seizes up with age. Even so, they still seem to give sufficient pressure to pass an MOT even on the 2 little pistons. So even if you think your brakes are in tip-top, it's still worth checking things out My old car had been standing for a few months, so when it went in for its MOT recently, it failed on brakes binding. I thought about levering things, but on closer inspection, the rubber components were brittle and the pistons were exposed looking very rusty After taking the wheel off, I took the pads out. This is so simple - there are 2 guide pins held in with little locking clips. Once removed the pads can be lifted out, measured, inspected and cleaned up. Taking the calipers off involves undoing 2 bolts that include a locking tab. Also disconnecting the brake pipe. I soaked these overnight in oil and I was lucky that they came off with little effort and didn't distort the pipe. Don't over force your spanner on these as they easy shear. Next, you need to extract the old pistons. Apparently, you should use an airline, but I don't have one and seeing as these pistons were scrap, I put the whole caliper in a vice and levered them out with a grip. They were tight, but came out eventually. Nasty looking! The corrosion build up is what makes the pistons jam up. Normally, they should float in and out on the rubber and not come into contact with the caliper body. All the old rubber needs to come out. I am lucky; I work for a shot blast manufacturer, so my calipers extraordinarily found their way into one of my customer's machines. After, I sprayed them in a high temp silver paint. A complete recon kit is available form Brookhouse including 3 pistons, 2 dust covers, 3 seals and a new bleed screw Fitting in the seals was easy. Fitting the dust covers was fiddly. Putting in the pistons was more than fiddly.
Now it's ready to go on the car making sure you remember the safety tab behind the 2 bolts. Reconnect the pipe, re-insert the pads, pins and locking clips. Bleed the system and surprise yourself by how bad the brakes were before!
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2006 XC70 D5 Manual 1968 Amazon Estate, B18A + Overdrive 2019 V60 D3 Momentum Pro Manual 1970 Amazon 2-Door 1970 142DL |
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May 16th, 2014, 17:25 | #2 | |
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Paul - 1967 Amazon 222S B20 o/d Estate & 1961 A-H Sprite Mk2 948cc WANTED - For '67 Amazon estate - offside rear quarter, preferably new old stock. |
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May 16th, 2014, 17:39 | #3 |
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Changing the brake fluid every 2. year will keep your brake calipers last longer, as brake fluid by time, sucks moisture and get the pistons to rust and size. I wonder why the pistons not are made of stainless material.
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Regards, Lars Jensen Volvo P1800E, 1972 |
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May 17th, 2014, 02:18 | #4 |
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They are available in stainless...
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May 17th, 2014, 07:07 | #5 |
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Good review Adam, thanks!
Did you consider breaking the calliper in two halves? I've seen arguments for both. Where are the stainless pistons available from? Russ |
May 17th, 2014, 12:07 | #6 |
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There is a Jag E type specialist in New York who has the little and large pistons available. Not cheap and unfortunately I can't find the link. Similar ones might be available from Jag spares companies here in the UK but I'd think a Volvo specialist somewhere would also have them.
An opportunity for someone in a machine shop somewhere perhaps? |
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May 17th, 2014, 13:14 | #7 |
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Of course Jag e types use the same calliper. What about Coopercraft?
http://www.coopercraft.co.uk/ Adam do you still have the old pistons? I need little and large to see what they say at work Russ |
May 17th, 2014, 16:41 | #8 |
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Maybe Brookhouse has them for Twin Circuit. If you google: Volvo p1800 stainless brake piston, you get this:
B) Front Brakes P1800 with Twin Circuit - Brookhouse Volvo ... http://www.classicvolvoparts.co.uk/p...ID=32&scID=174 Volvo 1800 1800S 1800E 1800ES - G) Brakes - B) Front Brakes P1800 with Twin Circuit ... FRONT GIRLING BRAKE CALIPER PISTON. FITS ALL AMAZON & P1800 TWIN CIRCUIT ... REPRODUCDED IN STAINLESS STEEL. PLEASE NOTE ... But if you go to the link, there is nothing mentioned on Brookhouse site that the brake pistons are stainless. Better ask Simon at Brookhouse.
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Regards, Lars Jensen Volvo P1800E, 1972 Last edited by LMJ; May 17th, 2014 at 18:02. |
May 17th, 2014, 19:30 | #9 | |
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Apparently - don't laugh - a Sherpa calliper with 4 pistons bolts straight on and is a very, very good upgrade! Are you saying you want my old set of pistons? If you're getting a set made, I'll have another set to do my Amazon saloon
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2006 XC70 D5 Manual 1968 Amazon Estate, B18A + Overdrive 2019 V60 D3 Momentum Pro Manual 1970 Amazon 2-Door 1970 142DL |
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May 17th, 2014, 21:35 | #10 | |
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Will See what I can do! Thing is loads of work going thru the company at the moment and 'rabbits' getting harder and harder to sneak in. Perhaps if we can show there is a market it may be easier. Perhaps we can supply Simon??! The dual CCT calipers are 4 pot I believe so therefore not suitable for the earlier cars You going to the Southern BKV tomorrow? Russ |
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