Help! Caliper won't go over disk.

[TREVCOS]

Hi folks, can someone offer any advice because this is driving me up the bloody wall.

Basically, I had trouble attaching the drivers side handbrake cable to the rear drivers side caliper, but got there in the end, but in the process pushed the caliper piston out. So I got a tool to wind it back in but even though it's now wound all the way in, I can't see how it could be wound in any further, when I put the pads in and try and get the whole lot over the disk it will not go. I keep trying it but I'm basically just going through the same process over and over again and getting absolutely nowhere. Anyone got any ideas? I'm completely stumped. The passenger side one went on no bother at all by the way.
It's a 300mm rear disk conversion with new standard calipers and new pads by the way.

Any advice would be appreciated to save my sanity.

[Cochyn]

Are you trying to fit the caliper on with the handbrake cable attached? Try loosening the adjuster in the centre of the cable and give yourself more leverage on the caliper to fit over the disc. The caliper piston shouldn't need to be wound all the way in, only to the point where its flush with the surface of the caliper.

Otherwise, use a mallet and lightly tap the caliper onto the disc. Sometimes they can have a tight fit. I remember swapping someones brakes for them once, and instead of trying basic options, the guy took a brake pad and grinded down the pad about 3mm just to fit it over the disc......tit!

[Sunnysidebb]

Hi folks, can someone offer any advice because this is driving me up the bloody wall.

Basically, I had trouble attaching the drivers side handbrake cable to the rear drivers side caliper, but got there in the end, but in the process pushed the caliper piston out. So I got a tool to wind it back in but even though it's now wound all the way in, I can't see how it could be wound in any further, when I put the pads in and try and get the whole lot over the disk it will not go. I keep trying it but I'm basically just going through the same process over and over again and getting absolutely nowhere. Anyone got any ideas? I'm completely stumped. The passenger side one went on no bother at all by the way.
It's a 300mm rear disk conversion with new standard calipers and new pads by the way.

Any advice would be appreciated to save my sanity.

With the risk of stating the obvious, have you tried to push the piston in using a flat bar/driver etc. Last resort, loosen the bleed nipple and push the piston in as you offer the caliper over the disc.

[georgie1]

as above trev back off handbrake adjustment and if you stil got fluid in caliper or air you wont get piston all the way back so undo nipple and piston may go back a bit more

[TREVCOS]

Are you trying to fit the caliper on with the handbrake cable attached? Try loosening the adjuster in the centre of the cable and give yourself more leverage on the caliper to fit over the disc. The caliper piston shouldn't need to be wound all the way in, only to the point where its flush with the surface of the caliper.

Otherwise, use a mallet and lightly tap the caliper onto the disc. Sometimes they can have a tight fit. I remember swapping someones brakes for them once, and instead of trying basic options, the guy took a brake pad and grinded down the pad about 3mm just to fit it over the disc......tit!

Yes, I've attached the handbrake cable, which was also a nightmare on this side, but I have loosened the adjuster as well.

I think this would be more than a tight fit, you can see that there isn't space between the pads and the caliper when you offer it up.

If I put either pad in, but not both, it goes over okay, as I guess it would, but put both pads in and no joy.

[TREVCOS]

I'll try opening the nipple and see, but it looks as if it's wound back as far as it will go to me.

[Cochyn]

Yes, I've attached the handbrake cable, which was also a nightmare on this side, but I have loosened the adjuster as well.

I think this would be more than a tight fit, you can see that there isn't space between the pads and the caliper when you offer it up.

If I put either pad in, but not both, it goes over okay, as I guess it would, but put both pads in and no joy.

Ah, well in that case it sounds like the piston isn't wound enough to be flush with the caliper face. Do as suggested, but the cable should be very easy to fit with the cable adjuster fully loosened

[TREVCOS]

Ah, well in that case it sounds like the piston isn't wound enough to be flush with the caliper face. Do as suggested, but the cable should be very easy to fit with the cable adjuster fully loosened

Even with the adjuster undone it was a git of a job, with it tightened up there was no way it would go. Oh well, I'll go and have another look.

Thanks for the advice guys.

[richyx]

get a pic of the piston on the caliper please

also how are you doing it?

what id do is put caliper carrier on, then fit pads into carrier then attach caliper, as you can use the pads against the disc as a lever to get the caliper on

[the youth]

have you got the piston set correctly against the pad, there is a tab on the back of the pad that sits in one of the 4 holes in the piston (the piston front has a cross in it) you need to turn the piston so that one part of the cross is vertical so that the tab on the pad sits in it, that will give you about 3 mm extra clearance than is it's not lined up.

steve

[The Radman]

presume you have located the lug on the back of the pad in the notch on the piston trev?

[TREVCOS]

presume you have located the lug on the back of the pad in the notch on the piston trev?

Yes mate, I've managed to get it on now, but it is pretty tight compared to the passenger side. Hopefully it'll be okay though.

Thanks for all the advice guys, I'm hoping I'm there now, we shall see.