Lancia Motor Club

I am thinking of starting a winter project, and am after some advice if anyone can help please?

I am looking to remove rear calipers on my PF, to upgrade with Aluminium cylinders (BG Developments). I have done the front brakes with success - see attached.

Is it really practical to attempt this, including renewing brake pipes in situ? Top bolts for the calipers look tricky, not much space for the lower one even. Do the half shafts/couplings need to be removed. Is it easier to drop gearbox anyway, and possibly replace discs at the same time (are rear disc available anyway????)

Any advice welcome....polite please!  ;D

What are the reasons NOT to drop the gearbox?  The brakes will need bleeding anyway. 

David

Nice looking brake assembly. I have removed/refitted the pistons, pads and pipes in situ, callipers probably require at least partial dropping of the transaxle.If the discs are available I would remove the transaxle and do every thing at once. I have had a spare pair skimmed, (yet to be fitted) as there was plenty of material remaining

It is possible to replace them in situ (I've done it on mine) - getting access to the top bolts from the boot access panel

However if you plan to replace the discs you may as well drop the whole trans

Thanks very much for your replies.

I will remove transaxle and do the calipers and disc all in one hit, as you suggest. (also the clutch whilst I am at it)

Any suggestions on how to lift/lower gearbox? It looks formidably heavy! I have car on 4 post lift.

Anybody know how heavy flaminia transaxle is?

60 Kilos?

Thanks Richard.

I was thinking of using a scissor lift to lower assembly, which is rated at 300kgs.....I would have thought the transaxle is less, but wanted to cross check, as the consequences would be dire. Sounds like I would be safe with this.

It is done ....and I still have all my limbs! :D

Well done Charles, next task, clean everything!!!

It will be so much easier to check everything and do the necessary work with the unit sitting there bereft of car !!!!!

                                  Andy

Any ideas what this sensor is for on gearbox selector? Reverse light?

I am sure you are correct about the switch, I cannot comment, but would just like to say how nice your car looks from underneath ! All clean, neat and tidy ....

Good luck

Thanks very much  ;D

I do like seeing all the hidden bits.  Well done!!   Easier than feared or a job that went on and on?

David

It was all relatively straight forward. The axle shackles required some persuasion. It's just finding the time and having the confidence to start!

Brakes and discs removed. Caliper bolts are difficult to access, so I removed handbrake assemblies and pipe work first. Caliper pistons were very stiff in cylinders. I dont know how I would have disassembled without transaxle removed from the car.

Reference the reverse selector switch ( for reversing light) mentioned earlier in thread, I am pretty sure that this is what it is, but I cannot see it listed in the Parts manual. My car seems to have a lashed up system (see photo) probably because the sensor failed at some point in its history. I have removed the sensor and it has a small probe which appears to have lost it 'spring', so no longer protrudes as necessary. Any body have a clue if the sensor is available or repairable?

Clean gearbox!  ;D

That looks really good Charles. Now you can begin to play without getting yourself and, more importantly, components covered in gritty dried up grease.

Good luck with whatever stripping and dismantling is required.


                                                 Andy

Good progress.

What did you use to clean it?

David

Thanks guys.

I used the 'green' version of GUNK, which seemed to work ok, with a bit of scrubbing.

The calipers have been sent off to BG Developments for plating (claw) and new cylinders and pistons as shown earlier in thread (anodised aluminium and stainless pistons). They supply Viva-Lancia if you have seen them on their website.

I am hoping they can manufacture new discs for me, but will keep you posted!

Omicron have supplied new gearbox mounts and a reverse light switch.

Happy days!

Charles

If you are struggling for discs, let me know - I have some spares that will skim.

Dave

Thanks for the offer Dave.

The old ones are pretty good with plenty of thickness ( 12.5 mm). They are a little pitted in places but will clean up.

If I can get new ones, in theory I will not have to remove gearbox again for a long time, or ever!

Look what Santa brought!

Happy Christmas.

Just a quick update.

Omicron kindly suggested stripping/cleaning/reassembling/greasing rear axle 'pots' would be a good idea, whilst off the car. These items are not serviced very often, and apparently can be a cause of flaminia gearbox failures.
 
One done with new 'boot', and one to go.

Rear brakes all rebuilt and ready to go.

Looking very smart, job well done


P

Should stop well ! - looks great ...

How did you clean the calliper "saddles" - looks fabulous.

David

Great work Charles

One question - the gearbox 'filler cap' - that sits ontop of the transaxle - mine will not undo - I assume it's threaded - or does it just pull out?

The T is soft so I can't just hit it or it will bend and heat hasn't proved very fruitful - it's just softening the metal! Any ideas?

Cheers
Dave

Charles, that looks marvellous and I am sure there will be a commensurate improvement in the braking power. With rebuilt pot joints you have a done a great job.

                      Andy

Thanks for all the comments guys. Lets hope it all works!  ;D

Dave, the 'filler cap,' or dipstick, is on a fine thread, so it should just unscrew.

David, the caliper 'claws' are plated. The aluminium brake cylinders and plating were done by those helpful chaps at BG Developments (as were the discs).

http://www.bgdevelopments.co.uk/index.php?option=com_content&view=article&id=71&Itemid=85

Thanks Charles - I was afraid of that - my dipstick/filler does not want to play!

I also have BG Developments piston assemblies all round - i'd also recommend!

Cheers
Dave

Hi Dave

Just a thought...have you tried a 'freeze' release agent on the dipstick/filler itself, so that it shrinks a little. Sorry if this is stating the obvious, but it worked for me on a difficult spark plug once!

Regards Charles

Never used that stuff before - but it did the trick - many thanks!

Cheers
Dave

Car is now running and brakes work splendidly! Even the MOT man was impressed.  ;D

Bleeding the brakes was very difficult, until I made a 'custom' spanner.