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Thread: Handbrake cable replacement...

  1. #31
    Join Date
    Apr 2009
    Location
    Ecosse
    Posts
    3,595
    All sorted.
    Ramped up the adjusters and the free travel disappeared. Good - well not altogether. The ratchet tang (pawl) on the adjuster on the OS had a bit broken off (fell to the ground) so adjustment could creep the other way. Plundered an old usable one and all sorted now.

    Thanks everyone for the help and advice - appreciated as ever.

  2. #32
    Join Date
    Nov 2007
    Location
    BANCHORY
    Posts
    3,294
    Copied from one of my posts somewhere else:

    Ignoring brake calliper faults, worn pads, worn out brake discs, faulty ABS unit and air in hydraulic system, the main causes for excessive brake pedal travel are:
    1) Stiff or seized hand brake cables. Hand-brake lever (7) on trailing shoe does not come to a rest at its "stop peg". This upsets the auto adjuster mechanism leading to excessive air gap between shoes and drum.
    2) Worn brake shoes.
    3) Incorrecly fitted springs and drum brake auto adjuster.

    The Bosch Simplex auto adjuster mechanism is preset with a rather large air gap. Brake pedal has to travel a considerable distance just to move shoes the required distance until they make contact with drum. Pedal travel can be improved by manually turning the brake-adjustment pinion (11) a maximum of 12 clicks but no more. Warning: Don't turn too high or it will be difficult to remove drum and shoes will drag. About 8 clicks is about right if the adjuster is working as intended and there is not too much run out in drums.


    Left hand side brake assembly with seized hand brake cable. Stop peg does not come to a rest against web of trailing shoe.


    Right hand side Bosch Simplex drum brake assembly as fitted on a Smart 450.


    Right hand side Bosch Simplex automatic brake adjuster. Note that the threads on the adjuster screw (16) are drawn incorrectly in the line drawing. Right hand side automatic brake adjuster has left handed threads whilst left hand side automatic brake adjuster has right handed threads.


    How to turn brake-adjustment pinion (11):
    Depress brake pedal a wee bit and hold in position with a suitable wooden stick or similar. Do this whilst drum is off on the side you are adjusting. Take care not to depress brake pedal too much or cylinder pistons will pop out. Depressing brake pedal a wee bit takes the compressive force off the brake-adjustment pinion so it can be turned by hand.
    Last edited by tolsen; 25-04-2018 at 01:27 PM.
    Drives a Smart Cdi - 65 to 85 MPG

  3. #33
    Join Date
    Mar 2012
    Location
    Burnley
    Posts
    1,371
    I did the brakes on this yesterday in order to MOT it.
    http://rollingpast.com/small%20Ambulance%201.jpg

    Believe me when I say your problems are not real ones.

  4. #34
    Join Date
    Apr 2009
    Location
    Ecosse
    Posts
    3,595
    160kg each side on the MOT rollers today. Job done!

  5. #35
    Join Date
    Mar 2012
    Location
    Burnley
    Posts
    1,371
    Quote Originally Posted by pinger View Post
    160kg each side on the MOT rollers today. Job done!
    How many people does it take to mend the handbrake on a Smart Car?

    Answers in writing please.

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