Brake Clunk/Spring Rattle/Long Pedal

[Titus A Duxass]

Hi all,
We've just done a front suspension rebuild and replaced all the flexi brake lines on my Pritsche (1988).
We now have the following issues:

1. Long brake pedal travel but when we put the handbrake on we have a pefect pedal. The local Bulli specialist has just replaced the handbrake cables (siezed). Is this bleeding or do the shoes need adjusting?

2. When I brake there is a single clunk as soon as pressure comes on the brake system, the calipers are tight. Is it likely to be the sliding pins?

3. It sounds like the springs are rattling on the lower arms. The springs have a rubber cover that goes up into the pocket in the body. There is nothing on the lower end of the spring, it just sits on the lower arm - is this correct?

[bigherb]

1. Long brake pedal travel but when we put the handbrake on we have a pefect pedal.

That indicates the shoes need adjusting or weren't centred correctly.

2. When I brake there is a single clunk as soon as pressure comes on the brake system, the calipers are tight. Is it likely to be the sliding pins?

Possibly or the pads are moving in the carrier.

3. The springs have a rubber cover that goes up into the pocket in the body. There is nothing on the lower end of the spring, it just sits on the lower arm - is this correct?

Yes for the front suspension. Was the spring seated in the recess for the end of the spring?

[Titus A Duxass]

Bigherb,
Thanks for your input.

That indicates the shoes need adjusting or weren't centred correctly.

Our thoughts as well. I will try and adjust them, do I need the special tool for this or is there a trick?

Possibly or the pads are moving in the carrier.

Is there a fix?

Yes for the front suspension. Was the spring seated in the recess for the end of the spring?

I'll take a look at them this eve.

[Titus A Duxass]

Aaaah!
My mechanic thinks he may have installed the front shocks incorrectly and they are clattering about.

He put the large rubber bush on the top, then the dished washer (concave side to the bush) and then the lock nut.
Should there be a bush between the top of the bump stop and the suspension turret/pocket?

[bigherb]

You can make a brake adjuster out of a 1/4" flat blade screwdriver, also handy for removing and installing the rocker cover clips.




Adjusting the brakes assuming they have been installed correctly .
Remove the wheel and half remove the drum, then adjust the shoes up making sure the top and bottom of the shoes are equal distance from the drum, especially the rear shoe as that's the one that doesn't self centre.

After callipers have been refurbished and the rust has been removed the pads can be a loose fit, usually cures itself once the brake dust and more rust takes up the slack, some brake pad tolerances can also be a bit slack.

How the rear brakes should be assembled.

[bigherb]

Assuming you have the later forged lower track control arm.

[Titus A Duxass]

Okay the shocks have be fitted correctly.

This is how the spring is sitting.



The mechanic thinks that the ARB is pushing the arms down too far. We did fit a later (thicker) ARB. Is there a compatibility problem?

[bigherb]

The spring should be fitted properly into the recess.

The mechanic thinks that the ARB is pushing the arms down too far. We did fit a later (thicker) ARB. Is there a compatibility problem?

Shouldn't be. The damper limits the downward movement of the track control arm. The ARB just swings up and down on level roads without exerting any force, only when one wheel is higher does it come into play. It actually tries to lift the lower wheel the reaction trying to keep the body level.

[Titus A Duxass]

Cheers.

[Titus A Duxass]

A quick update.
The rear brake problem was indeed down to badly adjusted rear brakes.

The brake clunk was probably down to an incorrectly tightened bolt.

The springs have been reseated.

Going for a test drive this evening.

Thanks Bigherb for the assistance.

The forum is still the best place to go for technical advice.

[mshaw1980]

The forum is still the best place to go for technical advice.[/quote]

I disagree. Dont you remember the old advert?

"You cant get better than a kwik fit fitter, there the ones to trust"

[Titus A Duxass]

"You cant get better than a kwik fit fitter, there the ones to trust"

Silly bugger!

[937carrera]

"....kwik fit fitter...."

I use the phrase "Kwik Fit approach" when a garage starts changing all sorts of bits over because they don't know what is wrong and haven't done a proper diagnostic.