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Brake Caliper Fix

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Old Oct 5, 2017 | 10:50 AM
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Default Brake Caliper Fix

Unfortunately I've had my 85 under construction all summer. It was one of those situations where one thing led to another and after 31 years and 90K miles things were needing attention. But I digress. While doing the brakes I decided to replace the right rear caliper rather than rebuild it like the others. I decide to go with an AC Delco remanufactured (Rock Auto) unit thinking that it should keep my problems to a minimum. I went to bolt it on and had a leak at the hose fitting after final torque. Now mind you, this wasn't a weeping leak, this was a constant drip leak with out any pressurization of the system. Turns out that the counter bore for the hose connection was machined too deep and the hose fitting was bottoming out on the casting. Well, my first thought was to just get a thicker seal washer. Nope, I already was using the thickest one the parts stores sold. So now do I send the unit back and take a chance that next caliper will fit and someone else will just get the same problem or do I just fix the problem. I compared the replacement caliper with my original and saw the difference. The original was fully machined around the hose port and the remanufactured caliper wasn't. I decided to just fix the problem myself and here is how I did it.
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Old Oct 5, 2017 | 04:19 PM
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for whatever reason, i'm surprised the remanufactured caliper wasn't fully machined - especially if was an AC Delco service replacement. anyway, you worked through the issue - job well done!
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Old Oct 5, 2017 | 06:54 PM
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While it may sound a bit on the redneck side - try using two copper crush washers - one right on top of the other. It's a heck of a lot easier than sending the caliper back !!!
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Old Oct 6, 2017 | 08:16 AM
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Originally Posted by Joe C
for whatever reason, i'm surprised the remanufactured caliper wasn't fully machined - especially if was an AC Delco service replacement. anyway, you worked through the issue - job well done!
Yeah, I was a little disappointed in that as well. Yup, worked through it and moved on. Thanks.

Originally Posted by Purple92
While it may sound a bit on the redneck side - try using two copper crush washers - one right on top of the other. It's a heck of a lot easier than sending the caliper back !!!
Sorry, but that was one solution I had thought of and quickly dismissed it. It is just not the way I do things.
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Old Oct 8, 2017 | 03:07 PM
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Default You don't want to take chances with your Brakes!

I agree with you, yes you can "make" it work or you can do the job "correctly". I agree with your final decision. You don't always get a second chance when you don't fix your brakes the "right way" the first time.

I too liked your design for the device allowing you to install your differential. A very creative solution to the problem at hand, I commend you for your creativity and drive.

I am still trying to get "permission" just to be able to buy a lift for my garage. I bought a house that had one installed but the owner would not convey it with the house...

If "he who dies with the most toys wins", I now understand your smile!

Keep coming up with those ideas of yours, better yet keep sharing them with us!

Good Luck and Thanks for the great ideas!
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