Rear Brake Calipers

[Twincam.GTi]

Yesterday afternoon noticed Handbrake was 'coming up to many clicks' on my AE92 GTi so knew it was time for a look at rear calipers. Thankfully drivers side caliper just needed a bit of a clean (slide area gets a bit dirty sometimes) and now 'grabs' properely again.

Although I realise rear caliper seizing/handbrake problems must be the most common mechanical problem with the AE82 GT, AE86 GT rwd, AE92 GTi and MK1 MR2; I did wounder if later versions of 'sporty' Corolla fitted with rear disc brakes are giving problems, such as the AE101 GXi, AE111 G6R, AE111 'Facelift' SR and even later 'Levin' coupes.

Just curious if Toyota ever 'sorted it' on later models?

[idiorock]

yea the gxi seems to suffer quite bad on that also

[JT]

how tight are the caliper bolts meant to be on the rear calipers? a few weeks ago, i tried to remove one of the calipers to clean it and re-lube the sliders, as the handbrake has stopped working on it. only it was that tight, i couldnt undo it. the spanner started to round the nut off (so i stopped!) and there was a suspension link directly behind the bolt so i couldn't get a socket on it.

also (off topic, but hey :D ) will i need to drop the fuel tank to change the pipe running from the filler neck to the tank, as it's leaking somewhere (no doubt the pipe will be stupid money!)

[System~G]

MKII MR2 are also known to suffer from poor handbrake engagement after replacing rear discs and/or pads...

Must just be a Toyota thing...

The most common thing people overlook when replacing the caliper after changing discs/pads is not unwiding the pistons aproximately 180 degrees after it has been fully wound in. This aligns the cylinder protrusion and the piston stopper groove.

Follow these instructions to the "T" and you should be fine. Click on relative link on left hand side. This link also gives a comprehensive guide to stripping and re-building the caliper.

Braking System Link - Clicky

Also a must read for those with earlier Toyota (AE82/86/92, AW11 etc...):

Brake Query Post on IMOC Link - Clicky

[Twincam.GTi]

System~G

The most common thing people overlook when replacing the caliper after changing discs/pads is not unwiding the pistons aproximately 180 degrees after it has been fully wound in. This aligns the cylinder protrusion and the piston stopper groove.

yep, don't remind me about it, 8 years ago a friend of mine had hers changed on an MR2 (Was a high miler)buy a garage and guess what ...

:censor: :censor: :censor:

"One did wounder how the 'Urchin' of a mechanic was going to remove a wheel brace from where the 'sun don't shine' if I had got hold of him!

[Twincam.GTi]

JT Posted

also (off topic, but hey  ) will i need to drop the fuel tank to change the pipe running from the filler neck to the tank, as it's leaking somewhere (no doubt the pipe will be stupid money!)

I knew there was something else to mention when listing faults on AE82's and AE92's.

Corroded Filer pipes is another common problem.

"I'm goin' to "Phone a friend" 'cause he's just done one on a 1988 AE92 GTi"

[Twincam.GTi]

i'm Back ... Just been in conversation with him...and you ain't gona like it!

Car he did it on was a 1988 Corolla GTi (That he said was on 'it's last legs' and will not go through another 'test' in 3 months time) and what he did was a bit of a bodge due to state of car (not actually worth spending on!).

Also don't know how applicable will be to AE82 GT.

The tank does not need to come off at all. Undo the screws at the filler neck opening end (that hold the black plastic shroud in) and go in from that way. Also plastic inner wheel arch does not need to be removed. At other end filler pipe is attached to tank 'junction' with a sort of jubile clip (is stainless so corrosion should not be a problem).

However are you sure its the filler pipe (on this example it deffinitely was 'cause it collapsed in the middle when filling up with fuel ) as the adjacent breather pipe that runs along side it can also rot (to repair this a bit of rubber tubing is fine) if it does rot it can make the rear of your car stink of fumes.

Anyway back to the actual filler pipe: I am afraid that a 'bodge' was now carried out because a new pipe from Toyota (genuine item only) would be around £150 plus my friend (who runs a garage) could not find an opropriate piece of pipe (exhaust sections etc.). So a piece of pipe was cut to bridge the rottern gap, rivited (don't go welding !!!!!!) and 'smothered in 'chemical metal' filer and left overnight, yes an utter bodge (which my friend does not make a habbit of doing!) but car is only going to be kept running for a short while .

As said earlier this was applicable to AE92.

I was hoping he'd have discovered a pipe section that would do job, sorry.

[JT]

lol, i knew it would be some ridiculous prics, but £150

it is definitely the filler pipe, or the breather (but im 90% sure its the pipe - it looks very rusty). yep, the boot stinks of petrol, it leaves a little puddle every time i fill up, and i can't put more than half a tank in, because otherwise it flows back into the pipe and leaks

great, the MOT's in july and i already know it will fail on at least two things - handbrake and filler pipe. i cant understand why it's only one side the handbrake has stopped working on - it's really strong on the other, and they were both overhauled not long back

[andy_twincams]

yeah my ae82 calipers are gone only just passes mot(mates with the tester :P )

as for the filler neck i had to do one on my polo,removed metal and put on a rubber pipe-it wotked?

[Twincam.GTi]

JT Posted Today, 03:33 PM

i cant understand why it's only one side the handbrake has stopped working on - it's really strong on the other, and they were both overhauled not long back

When I have caliper/handbrake trouble it is only ever one side or t'other.

Incidently both my calipers have oversized and re-tapped fixing nuts/bolts due to originals rounding off (one actually snaped clean off).

[RedAE102]

One of the handbrake cables on my AE102 has seized, been that way for over a year now. I finally got the brake proportioning sorted, so the handbrake is the next and final item on my list that I need to fix... in terms of brakes, that is. Thankfully, we don't have comprehensive state safety inspections, just the infamously brutal California biennial "Smog Checks," and more importantly, that I don't live or have to park in a hilly area! And yes, my rear calipers were replaced with overhauled units about a year ago. On the other hand, I haven't had a single problem from the front calipers (crosses fingers and eats words before they have a chance to come around and bite me from behind :!Removed!:).

[Twincam.GTi]

RedAE102  Today, 09:11 AM Post #11 

Location:Cypress, California, US

Thankfully, we don't have comprehensive state safety inspections,

Oh my ,

You must have a lot of accidents!

I know there would be a lot of incidents in Britain if it wasn't for the M.O.T :D

[RedAE102]

RedAE102  Today, 09:11 AM Post #11 

Location:Cypress, California, US

Thankfully, we don't have comprehensive state safety inspections,

Oh my ,

You must have a lot of accidents!

I know there would be a lot of incidents in Britain if it wasn't for the M.O.T :D

←

We have a lot of accidents, but mainly because people around here refuse to exercise common sense. And, at the risk of sounding racist or ignorant (I'm not, just making an observation), we have way too many illegal immigrants without licences or insurance driving around here. Most other states in the union have safety inspections, and I was only stating that I'm thankful that we don't have the safety inspections because of my handbrake cable, and that I was able to put off buying new ones until I could find a decent deal on them. Other than that, I completely advocate an annual safety inspection in California, as long as they are a little more relaxed on the smog checks. Right now, if they see a non-standard part on the engine that doesn't have a CARB (California Air Resources Board) exemption number, such as an intake or an exhaust header, we automatically fail the smog check, even if the car's exhaust emissions are well within the legal limits.

My car originally came with rear drum brakes (USA and Canada are the only places in the world where the AE102 models didn't come with 4-wheel discs... and I'm not generalising E10s, just the AE102s). I swapped in a set from an AE101 Levin Coupé. They had been sitting a while, so the calipers were seized. The handbrake cables were still intact (or so I thought), as most of the other ones I found had been cut. I was able to replace the calipers using parts here because we did get the AE82 and AE92 with rear disc brakes, and they use the same calipers as the AE101/102/111/112 and ZZE112, just with taller mounting brackets to accomodate the 266 mm rotor versus the AE82/92's 242 mm rotor. I'll shut up now.

[Twincam.GTi]

RedAE102 Posted Yesterday, 10:54 PM

 

My car originally came with rear drum brakes (USA and Canada are the only places in the world where the AE102 models didn't come with 4-wheel discs... and I'm not generalising E10s, just the AE102s). I swapped in a set from an AE101 Levin Coupé. They had been sitting a while, so the calipers were seized. The handbrake cables were still intact (or so I thought), as most of the other ones I found had been cut. I was able to replace the calipers using parts here because we did get the AE82 and AE92 with rear disc brakes, and they use the same calipers as the AE101/102/111/112 and ZZE112, just with taller mounting brackets to accomodate the 266 mm rotor versus the AE82/92's 242 mm rotor. I'll shut up now.

No, no please don't 'shut up now' that was my original question ("do the later models with rear disks suffer as well as AE82 and AE 92 GTs?!) so thanks for that. Also didn't realise calipers were same as later models (apart from taller mounting) that is very useful to know, thanks

RedAE102 Posted Yesterday, 10:54 PM

We have a lot of accidents, but mainly because people around here refuse to exercise common sense. And, at the risk of sounding racist or ignorant (I'm not, just making an observation), we have way too many illegal immigrants without licences or insurance driving around here.

Yes, we have the same problem in Our country. In the Newspapers this last month there have been two cases of imigrants driving with no licenses/insurrance etc and in both cases being involved in accidents. The one invloved killing a mother and child as he ran into the side of their car and the other mounted a pavment and also killed a pedestrian (again I think this was a child), No sir, you do not sound racist or ignorant, you sound concerned in the same way the rest of us are. Perhaps I should shut up now (as I have now gone a little of topic, sorry).