Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

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ROVER-25X
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Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby ROVER-25X » Sun Jun 18, 2017 5:25 am

Following on from my Cabby update thread I though I would post up what I get upto while on a boring
night shift at work, a good old tidy up of the crusty Turbo brakes that dist donated to the cause. :D

As you can see, just a tad scabby. :blink





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I started on the carriers, the first one came out ok.



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Once they were free of surface rust I cleaned up the slider pins, some dryish black grease in most with a
hint of copper slip on a couple, all cleaned up and lathered in fresh brake grease, I then taped up the rubber
covers and set about getting them primered up.



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Then it was time for paint ! :blushing



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Not everyone's cup of tea but the logic behind the yellow it the fact the brand new suspension struts are
also bright yellow so I though it would look smart, plus I am only doing the carriers in this colour, the
calipers themselves will be a gunmetal grey to make the carriers stand out.

As for the calipers, I made a start on them as they too were quite crusty with surface rust, took a while
to wire brush them with the drill as it lasted about 6-7 mins before requiring a charge. :laughing2

You can really tell the difference with one done, the surprising thing is the worse one came out better ! :blink




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Now awaiting the seal kit to be fitted. :D


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Last edited by ROVER-25X on Thu Jul 13, 2017 3:30 am, edited 3 times in total.
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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby 1374lee » Sun Jun 18, 2017 2:30 pm

Nice work, they have come up so much better after removing all the crusty surface rust. What make are the bright yelow shocks you have?

Thanks. Lee.

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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby ROVER-25X » Wed Jun 21, 2017 11:18 pm

Can't remember, bought them months ago, they are stored in the garage waiting to be fitted.
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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby ROVER-25X » Fri Jun 30, 2017 12:27 am

I still need to do the seals on the brakes, I have many hours to kill over the next couple of weeks,
125 and a half to be exact. :laughing2

I will make the most of the quiet shifts and attempt to finish off the brakes with new seals and
new paint on the calipers but I have never done the seals before, I found this video on YouTube
with a chap doing some HONDA CIVIC brake seals and the brakes look VERY similar to mine, is
this a good guide to use doing mine ?


https://www.youtube.com/watch?v=rf-ONbg9-os
ROVER-25X (2001 1.4 ROVER 25)
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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby ROVER-25X » Mon Jul 03, 2017 8:17 pm

I have now found this video which would be more helpful I suspect. ;)


LINK: https://www.youtube.com/watch?v=155109ONAKE
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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby Mr Teddy Bear » Tue Jul 04, 2017 5:00 pm

Never done the fronts, but if the same as the rears, then the worst job is refitting the external dust boots as shown in your pic's.

At the risk of teaching you to suck eggs the pistopn sticks due to corrosion of the [cromed ?] piston inside the dust boot. As he says in the second video, remove the pads and then use pedal pressure to push out the piston far enough to get some leverage on it, before disconnecting/clamping off, the flexi brake hose.

Warm the seals/dust boots in hot water before fitting.

Make sure all the shims are present and that the thing floats properly on the pins/sleeves. [ I'm sure you already know all this, just added for the benefit of other people reading the thread] :)
Teddy Bear

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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby ROVER-25X » Wed Jul 05, 2017 4:38 am

The calipers are mullered, no play or movement in either piston, messed with them for about 2 hours last
night, my mate said to soak them in diesel but the bleed nipples are also seized, might cut my losses to
be honest, might have to bit the bullet and buy new ones, the seal kit won't go to waste as they fit most
the calipers on the later Rovers.
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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby Mr Teddy Bear » Wed Jul 05, 2017 7:04 pm

If they have been left in the scrappy with the brake pipes cut off, thus air/moisture/corrosion getting into the piston chamber then likely to be U/S.
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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby ROVER-25X » Mon Aug 14, 2017 6:42 am

UPDATE: 14/08/17


So I had to lay off these calipers as they were seized solid, soaked them in some diesel then cleaned them off
again and I did the air compressor hack, you cut down a used tyre valve from an alloy wheel, shave it down and
push it into the banjo bolt hole ensuing the bleed nipple is shut, then using a tyre pump or a compressor tyre
inflater gently squeeze the pistons out, worked ok on one, got it 2/3 of the way out, an inverted 6" nail into
the banjo bolt hole and a light hammer tap got the first one out.

Next was the second one, I literally went in hard and pulled the trigger all the way and almost killed Stevo as
the piston exploded out with a massive bang, not only were we both deaf but Stevo got a face full of brake
fluid and diesel mist. :laughing2

.....worked though. :tt2




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With the pistons now out I could see what they were like inside, it was literally the smallest ring of corrosion
on each piston, that cleaned up with 1200 grit Wet & Dry with a little WD40, I then removed all the old seals
and binned them then cleaned up the channels, I gave the insides, the pistons, the bleed nipple channels and
the main seal channels a good clean out with canned brake cleaner.




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The bleed nipples were still seized too but a bit of heat from the blow lamp loosened them up and out they
came to go straight into the bin.

Next to do was to fit the new seals, the main seals went in fine but the dust seals took me over 3 hours to do,
I eventually found a way to fit them and the piston, all sorted now.




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Next is to clean up the caliper bodies of grease and oil then prime them ready for paint, new bleed nipples and
new stainless banjo bolts are on the way so hopefully they will be finished by Friday or the weekend at the latest
and they can go on the Cabby with the new Brembo Pads & Discs, might even MOT it but wheels are an issue
at the moment.
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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby Julesmat50 » Mon Aug 14, 2017 11:22 pm

ROVER-25X wrote:So I had to lay off these calipers as they were seized solid, soaked them in some diesel then cleaned them off again and I did the air compressor hack, you cut down a used tyre valve from an alloy wheel, shave it down and push it into the banjo bolt hole ensuing the bleed nipple is shut, then using a tyre pump or a compressor tyre inflater gently squeeze the pistons out.

I've used a similar method to this in the past on non-Rover calipers, but used the (usually red) "football" inflator nozzle you get with a new foot pump and pressed that into the brake line. As it is tapered with a quite narrow end, it can even be held directly into the machined holes in the casting, with care. Holding the nozzle with one hand and using the other to operate the footpump, gently eases the pistons out of calipers with the minimum of effort, unless they are really stuck solid.

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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby ROVER-25X » Wed Aug 16, 2017 8:11 pm

Very handy but I think unless your a cheapskate like me who will spend the few quid on bits to
rebuild rather than buy new calipers it won't be used by many *laughs*. :laughing2
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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby Julesmat50 » Wed Aug 16, 2017 8:20 pm

ROVER-25X wrote:unless your a cheapskate like me who will spend the few quid on bits to rebuild rather than buy new calipers

Through necessity, yup! :D

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Re: Refurbing Turbo Brakes for the Cabby - (WARNING Garish Colours)

Postby ROVER-25X » Fri Aug 18, 2017 1:20 am

Going to get the silver paint out this weekend, hoping to get them looking like these but with yellow not red carriers. :D




Image
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