MR2 GTi-16

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Fozzy
Posting Freak

1,132

01-03-2017, 04:38 AM

#61

To me thats not extortionate. On my old cavalier the bosch dizzy cap was 95 quid and anoth 25 for the rotor arm. Plus leads at 150 quid, it made for an expensive service item

2009 JAE Car Pull Runner Up
2010 JAE Car Pull Failure

My Garage

Fozzy

01-03-2017, 04:38 AM #61

To me thats not extortionate. On my old cavalier the bosch dizzy cap was 95 quid and anoth 25 for the rotor arm. Plus leads at 150 quid, it made for an expensive service item

2009 JAE Car Pull Runner Up
2010 JAE Car Pull Failure

My Garage

toxo
Posting Freak

4,843

01-03-2017, 04:42 AM

#62

lol, just checked through my emails, I remembered the cap wrong. It's £64 + vat :o

toxo

01-03-2017, 04:42 AM #62

lol, just checked through my emails, I remembered the cap wrong. It's £64 + vat :o

steviewevie
Posting Freak

7,993

01-03-2017, 11:10 PM

#63

Looks like you're cracking on well with sorting out a lot of the problems with your car, good work ! :thumbup:

IS200 Turbo project now just about complete ! See my thread here and leave your comments.
Now running standalone Syvecs ECU and no stock ECU !

steviewevie

01-03-2017, 11:10 PM #63

Looks like you're cracking on well with sorting out a lot of the problems with your car, good work ! :thumbup:

IS200 Turbo project now just about complete ! See my thread here and leave your comments.
Now running standalone Syvecs ECU and no stock ECU !

Fozzy
Posting Freak

1,132

02-03-2017, 01:18 AM

#64

Plenty of room now
[Image: DSC00532.jpg]

So the work began, i got the front end jacked up and on axle stands and the wheels off. It was at this stage i doscovered that the wheels were fitted without spiggot rings, so i will need to find some of those pretty soon. The brakes calipers are easy to remove, a 14mm on the brakes hose banjo, and two 14mm holding the caliper to the bracket. I clamped the hose to stop making a mess, but once the caliper was off, i removed the clamp and let the system drain out.

[Image: DSC00536.jpg]

The caliper was in a bit of a state when i removed it. They had been painted on the car, so as usual only half was painted. They were pretty filthy.

[Image: DSC00538.jpg]

To strip it down i used compressed air to push the pistons out. Unfortunately this only worked on one piston as the other was well stuck. I used a block of wood to stop the free piston from coming out so i could keep the pressure on the seized one. To help free it off i poured some brake fluid around the edges. After quite a long time of tapping the pistons in and then forcing them out, it eventually freed off, so i could get both pistons and all the old seals out. Unfortunately i dont have any pics of this satge and the cleaning up, as i was filthy by then.

[Image: DSC00541.jpg]

So i wirebrushed them off and degreased them, then gave them a coat of black hammerite. Its not a great finish, but a lot better than they were.

[Image: DSC00544.jpg]

So rebuilding the caliper. First off there is the main seal. This fits inside the caliper body. It is a solid rubber seal, and is quite easy to get in. I smeared it with a small amount of brake fluid first and slotted it in.

[Image: DSC00547.jpg]

Next i took the cleaned up piston and the main dust seal. A little bit of fluid on the seal and the bottom of the piston, and i slid the seal on.

[Image: DSC00556.jpg]

The seal fits into the groove at the top of the piston that you can see. Next i smeared some more brake fluid in the bore and slid the piston into place. It needed a bit of a press with a clamp to get it past the main seal, but once it was in it moved freely. The next fiddly bit was to get the dust seal seated into the caliper body and get the retaining ring in. Again i dont have any pics of this as i had brake fluid on my hands. The joys of working alone - i need a photographer.

[Image: DSC00555.jpg]

Finally the finished caliper

[Image: DSC00550.jpg]

Edited 13-04-2010, 10:54 AM by Fozzy.

2009 JAE Car Pull Runner Up
2010 JAE Car Pull Failure

My Garage

Fozzy

02-03-2017, 01:18 AM #64

Right i have some photos to go with the weekends work, plus another new discovery.

The day started with having a bit of a tidy up in the garage so i could get the car in there. This took me the best part of 3 hours. I now need to do a few tip runs to get rid of the 4 crates of rubbish and 7 gallons of used oil i bottled up.

[Image: DSC00527.jpg]

Plenty of room now
[Image: DSC00532.jpg]

So the work began, i got the front end jacked up and on axle stands and the wheels off. It was at this stage i doscovered that the wheels were fitted without spiggot rings, so i will need to find some of those pretty soon. The brakes calipers are easy to remove, a 14mm on the brakes hose banjo, and two 14mm holding the caliper to the bracket. I clamped the hose to stop making a mess, but once the caliper was off, i removed the clamp and let the system drain out.

[Image: DSC00536.jpg]

[Image: DSC00537.jpg]

The caliper was in a bit of a state when i removed it. They had been painted on the car, so as usual only half was painted. They were pretty filthy.

[Image: DSC00538.jpg]

[Image: DSC00539.jpg]

To strip it down i used compressed air to push the pistons out. Unfortunately this only worked on one piston as the other was well stuck. I used a block of wood to stop the free piston from coming out so i could keep the pressure on the seized one. To help free it off i poured some brake fluid around the edges. After quite a long time of tapping the pistons in and then forcing them out, it eventually freed off, so i could get both pistons and all the old seals out. Unfortunately i dont have any pics of this satge and the cleaning up, as i was filthy by then.

[Image: DSC00541.jpg]

[Image: DSC00542.jpg]

So i wirebrushed them off and degreased them, then gave them a coat of black hammerite. Its not a great finish, but a lot better than they were.

[Image: DSC00544.jpg]

[Image: DSC00545.jpg]

So rebuilding the caliper. First off there is the main seal. This fits inside the caliper body. It is a solid rubber seal, and is quite easy to get in. I smeared it with a small amount of brake fluid first and slotted it in.

[Image: DSC00547.jpg]

[Image: DSC00549.jpg]

Next i took the cleaned up piston and the main dust seal. A little bit of fluid on the seal and the bottom of the piston, and i slid the seal on.

[Image: DSC00556.jpg]

The seal fits into the groove at the top of the piston that you can see. Next i smeared some more brake fluid in the bore and slid the piston into place. It needed a bit of a press with a clamp to get it past the main seal, but once it was in it moved freely. The next fiddly bit was to get the dust seal seated into the caliper body and get the retaining ring in. Again i dont have any pics of this as i had brake fluid on my hands. The joys of working alone - i need a photographer.

[Image: DSC00555.jpg]

Finally the finished caliper

[Image: DSC00550.jpg]

[Image: DSC00551.jpg]

2009 JAE Car Pull Runner Up
2010 JAE Car Pull Failure

My Garage

Lexusboy
Posting Freak

9,267

02-03-2017, 01:21 AM

#65

Good thread Pete was it easier than you first thought?

Lexusboy

02-03-2017, 01:21 AM #65

Good thread Pete was it easier than you first thought?

toxo
Posting Freak

4,843

02-03-2017, 01:25 AM

#66

The dust seals with the retaining rings are a pain in the ****... FWIW you can still see the retaining clip in the right hand piston in 1st photo and in my experience that means the dust seal will be on your drive in a few days time.

toxo

02-03-2017, 01:25 AM #66

Fozzy
Posting Freak

1,132

02-03-2017, 01:26 AM

#67

Hmm thants not so good. New radiator to add to the list

Also for those with sharp eyes, you may have seen in the first picture a set of wheels on the right hand side of the garage. They are a set of Kahn RSR alloys i was asked to look after for a mate. That was 3 years ago and he now lives back in Ireland. They came with his mr2, so now they will go on mine. They need a refurb as the paint has flaked badly on a couple of them, but they are straight and haven't been kerbed. I will get them acid dipped then ill respray them in gold to replace the current wheels.

As i need the car as a daily, the 18's are a bit too much, so i will keep them as a spare set and for shows etc

[Image: DSC00529.jpg]

2009 JAE Car Pull Runner Up
2010 JAE Car Pull Failure

My Garage

Fozzy

02-03-2017, 01:26 AM #67

Right about that discovery i made. I was taking a look under the front bumper to see how the fog light is removed. It appears i need to take the bumper off to do it. As i was getting up i happened to look through the bumper at the radiator. I thought it looked a bit odd, then i realised why

[Image: DSC00552.jpg]

[Image: DSC00554.jpg]

Hmm thants not so good. New radiator to add to the list

Also for those with sharp eyes, you may have seen in the first picture a set of wheels on the right hand side of the garage. They are a set of Kahn RSR alloys i was asked to look after for a mate. That was 3 years ago and he now lives back in Ireland. They came with his mr2, so now they will go on mine. They need a refurb as the paint has flaked badly on a couple of them, but they are straight and haven't been kerbed. I will get them acid dipped then ill respray them in gold to replace the current wheels.

As i need the car as a daily, the 18's are a bit too much, so i will keep them as a spare set and for shows etc

[Image: DSC00529.jpg]

[Image: DSC00530.jpg]

2009 JAE Car Pull Runner Up
2010 JAE Car Pull Failure

My Garage

Fozzy
Posting Freak

1,132

02-03-2017, 01:28 AM

#68

toxo The dust seals with the retaining rings are a pain in the ****... FWIW you can still see the retaining clip in the right hand piston in 1st photo and in my experience that means the dust seal will be on your drive in a few days time.

I also noticed that in the photo. I will be removing that one and reseating it. The one on the other side has dropped into the groove nicely. And yes it was all faily smooth going. A bit of an **** to remove the seized piston, took over an hour in the end. Those dust seals are a right pain to get in, so fiddly

2009 JAE Car Pull Runner Up
2010 JAE Car Pull Failure

My Garage

Fozzy

02-03-2017, 01:28 AM #68

toxo The dust seals with the retaining rings are a pain in the ****... FWIW you can still see the retaining clip in the right hand piston in 1st photo and in my experience that means the dust seal will be on your drive in a few days time.

2009 JAE Car Pull Runner Up
2010 JAE Car Pull Failure

My Garage

steviewevie
Posting Freak

7,993

02-03-2017, 01:29 AM

#69

Good work Pete. I'd like to give my own calipers a service. Not sure I'm feeling brave enough to do it though !

IS200 Turbo project now just about complete ! See my thread here and leave your comments.
Now running standalone Syvecs ECU and no stock ECU !

steviewevie

02-03-2017, 01:29 AM #69

Good work Pete. I'd like to give my own calipers a service. Not sure I'm feeling brave enough to do it though !

IS200 Turbo project now just about complete ! See my thread here and leave your comments.
Now running standalone Syvecs ECU and no stock ECU !

Lexusboy
Posting Freak

9,267

02-03-2017, 01:32 AM

#70

Where have the rad fins gone?

Lexusboy

02-03-2017, 01:32 AM #70

Where have the rad fins gone?

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