jardon
Sunday 9th September 2012, 21:39
Just a quick story of my last weeks pottering. I bought a set of calipers and carriers labelled "2008 S60 2.4T" - on that basis Tim and I expected them to need 320mm discs as that's what a 2008 T5 has. They were ex-police I think as they came with pads that had the wiring for wear indicators.
I started last Sunday night by taking off the wheel and trying to get the flexy off the caliper.
My spanners were no good so I bought some B+Q brake pipe spanners. These were §§§§e and I was rounding the nuts. In the end I cut the old hose, got a mole grips and decent spanner at the body end of the flexi and it came off.
I drilled the 12mm hub carrier holes to 14 mm easily enough (aluminum) but then immediately blunted the bit when drilling the steering stop deflectors (steel). I had a hand drill on full speed so it overheated. My mate has a pillar drill so a new bit later we were sorted - the bolts were tight at the shoulder so we opened the holes out to 14.5mm to half the depth of the deflectors.
The disc and carrier bolted up nicely but there was 4mm spare disc at the outer edge and the pads were 4mm over the inner edge (discs to big or carriers too small). I also noticed that the caliper body was fouling a "nipple" that protrudes from the front of the deflector thingy - suggesting carriers too small.
I made a few calls that day to Tim, MRG and FRF and in the end we established that these calipers were used on 316mm discs on XC90's - that's the set-up I had. Either the breakers had wrongly labelled the calipers or they had genuinely come off a police car that had 316mm fitted - they do fit used parts so could easily have been the case. 320mm discs exchanged for 316mm and all looks spot on.
I then confidently moved to the off-side and snapped the fitting off the hard pipe. FFFFAAAAAAARRKK!! In all honesty by this stage I was laughing and as ever Tim talked me through it all. Last resort was dragging him here to flare the pipe in-situ (I didn't fancy getting that job wrong). Lucky for him I managed to get the pipe off the car (stuck a bleed nipple in to plug the ABS unit) and a mate sorted it.
After a lot of waggling the pipe is back on and the off-side caliper sorted. All bled quickly (used super blue in the end for ease) and the pedal is really firm - way better than before. This could be the new calipers as there is less room for flex or it could be that the pedal gets softer when your pads are worn - my old xp10's were quite low.
Test drive was lovely - firm pedal, XP8's great initial bite even from new.
I reckon there's a spare 10mm between the caliper and the wheel so maybe next time I'll source 336mm XC90 calipers!!
Thanks to Tim for letting me bother him pretty much every day week.
Every cloud though - I've been cycling to work all week and it felt really good.
I started last Sunday night by taking off the wheel and trying to get the flexy off the caliper.
My spanners were no good so I bought some B+Q brake pipe spanners. These were §§§§e and I was rounding the nuts. In the end I cut the old hose, got a mole grips and decent spanner at the body end of the flexi and it came off.
I drilled the 12mm hub carrier holes to 14 mm easily enough (aluminum) but then immediately blunted the bit when drilling the steering stop deflectors (steel). I had a hand drill on full speed so it overheated. My mate has a pillar drill so a new bit later we were sorted - the bolts were tight at the shoulder so we opened the holes out to 14.5mm to half the depth of the deflectors.
The disc and carrier bolted up nicely but there was 4mm spare disc at the outer edge and the pads were 4mm over the inner edge (discs to big or carriers too small). I also noticed that the caliper body was fouling a "nipple" that protrudes from the front of the deflector thingy - suggesting carriers too small.
I made a few calls that day to Tim, MRG and FRF and in the end we established that these calipers were used on 316mm discs on XC90's - that's the set-up I had. Either the breakers had wrongly labelled the calipers or they had genuinely come off a police car that had 316mm fitted - they do fit used parts so could easily have been the case. 320mm discs exchanged for 316mm and all looks spot on.
I then confidently moved to the off-side and snapped the fitting off the hard pipe. FFFFAAAAAAARRKK!! In all honesty by this stage I was laughing and as ever Tim talked me through it all. Last resort was dragging him here to flare the pipe in-situ (I didn't fancy getting that job wrong). Lucky for him I managed to get the pipe off the car (stuck a bleed nipple in to plug the ABS unit) and a mate sorted it.
After a lot of waggling the pipe is back on and the off-side caliper sorted. All bled quickly (used super blue in the end for ease) and the pedal is really firm - way better than before. This could be the new calipers as there is less room for flex or it could be that the pedal gets softer when your pads are worn - my old xp10's were quite low.
Test drive was lovely - firm pedal, XP8's great initial bite even from new.
I reckon there's a spare 10mm between the caliper and the wheel so maybe next time I'll source 336mm XC90 calipers!!
Thanks to Tim for letting me bother him pretty much every day week.
Every cloud though - I've been cycling to work all week and it felt really good.