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.