Rear Brake Caliper E-Brake Retractor

[Martin101]

I've rebuilt a pair of rear brake calipers for a 1978 Fiat Spider and an looking for input before I install them into the vehicle.

I reassembled the caliper pistons in to the e-brake plunger and have reassembled the e-brake retractor arm along with the pivit 'wedge' between the plunger and retractor arm. Anybody who has done this knows what kind of knuckle busting experience this is.

Now that the reassemble is complete, if I manually push the e-brake retractor arm to push the piston out, the piston does not go out like I would expect it to in order to push the brake pads against the rotor - keeping in mind the caIipers are not installed in my vehicle and still in the vice on my workbench.

What type of play should I expect out of the e-brake retractor arm and the piston before the calipers get reinstalled into the vehicle?

Would this install process be as follows : install the calipers (brake shoes, etc) - bleed the brakes - connect the e-brake cable to the retractor arm/brake caliper - make the e-brake adjustments?

Are there any manual adjustments I should be aware of before I proceed with the installation? I'm a newbie to working on Fiat's and this brake caliper rebuild has thrown a couple of curveballs my direction.

A couple of notes for those looking to rebuild their rear brake calipers:

1) when disassembling the e-brake retractor arm, piston plunger, and 'pivit' wedge between the plunger and retractor - pay close attention to how they reassemble between the plunger, retractor, and wedge. This is a rubics cube the first time you try it yourself.

2) make very specific notes when disassembling the piston and it's internal mechanics and be aware that there are a number of pieces inside that can be damaged easily when disassembling. I'd advise to clean without disassembling.

3) when reassembling the retractor arm into the caliper, be very careful not to push the bushings out as they are very soft metal and will not go back in easily. If they are damaged you will have to either modify another bushing to fit the fiat caliper or purchase new/rebuilt calipers.

You can probably tell from my notes how this rebuild has gone so far :)

Thanks for all help and input -

Martin101

[manoa matt]

Martin,

This should help a little, but it seams like you figured it out. http://www.mirafiori.com/faq/content/re ... lipers.htm

The e brake retractor should move freely, if it is very difficult double check the orientation of the wedge and the tangs at the end of the center rod on each side of the wedge.

It does not move the piston that much, maybe a few mm. You order of opperations seams fine. When adjusting the e brake cable you want the calipers to grab after 2-3 clicks of the handle.

The important thing to note: Look very carefully at the last picture in the article. The piston must be oriented that way or bleeding the rear brakes will be difficult if at all possible. There is a line inscribed in the exposed piston face. If you hold the caliper as it would be installed on the car the line will be horizontal and on the top side.

Also disconnect the linkage for the rear brake compensator at the axle, push it up and support it. It will open the rear brake valve and make bleeding easier. Make sure you support the rear of the car by the axle and not the body/frame.

[Martin101]

Thanks Mike! This is just the feedback I was looking for - your info will definately save me time redoing errors.

[manoa matt]

MATT

[wachuko]

MATT

That was a great link Matt. Downloaded to my documents folder. Maybe I can revive the rear calipers from the parts car. Front ones are inexpensive at 38.00... rear ones go for around 90.00 per corner. Best to have a working spare just in case.

[Martin101]

Sorry Matt. Didn't mean to get your name wrong - just wanted to quickly post a thanks... a little too quick it appears. Thanks again for the info. It certainly helps.