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Date:         Sat, 18 Jun 2011 21:09:16 -0400
Reply-To:     Ed <email99@BELLSOUTH.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Ed <email99@BELLSOUTH.NET>
Subject:      Re: Problem: While Removing from Disc Brake Pads the top Caliper
              Receiving Bolt Wont Slide In & Out of the Carrier - Siezed

If you replace anything it needs to be the pins and the carrier. The pins just bolt to the caliper, but they slide in the carrier. Replacement pins are available at major parts suppliers although it might be difficult to find the exact part number. Since they are available, if you destroy the old ones trying to get them out of the carrier it is OK. You can soak the stuck pins with liquid wrench, put your vice grips on the pin and try to twist it out. Then clean up the hole in the carrier as described earlier in this thread. Lube the new pins with plenty of synthetic wheel bearing grease and reassemble with new pins. They must slide easily and a little extra play between the pin and carrier is OK.

This is important: The pins must be absolutely parallel when assembled. If they are bent or are not orthogonal to the mounting surface (i.e the pin is perpendicular to the plane of the top surface of the pin) the caliper will be frozen when assembled as you have experienced. This will cause the brakes to drag and overheat, possibly resulting in destruction of the grease seal and soaking the disc with grease. It's not a pretty sight. I know this from buying rear disc brakes from a list vendor. The calipers and carriers were assembled during shipping and the over weight, improperly packed box was dropped in shipping, resulting in bending the slide pins. As a result, the calipers would not slide when all was assembled and tightened up. I didn't realize this and after the first 300 mile trip the brakes were soaked with grease and scorched to a bronze color. Only after turning the discs, replacing the pins and pads, repacking the rear wheel bearings and replacing the grease seals was the problem fixed. BTW, the vendor was no help at all.

You might be able to just clean up the pin and the hole that it slides in but remember that this absolutely has to work easily or your brakes will drag and overheat. Make sure the caliper will slide in the carrier when the pin mounting bolts are tightened without the pads in place. Then remove the caliper and install the brake pads.

Work carefully. Brakes are simple but they have to be done right. If you are not sure that you understand what you are doing, seek professional help.

Ed

> > >Replace the caliper.


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