Public Thanks (Brake Rebuild 101)

[Osman Parvez <oparvez1@nycap.rr.com>]

Hi Folks, 
   I spent Saturday in the company of Igor Kessel down in Philly who had
volunteered to guide me in rebuilding my brakes. After aquiring the
parts, and with one 2 hour delay, I was there by noon at Igor's place.
   
   We ran into a large number of problems in rebuilding my brakes. Most
were attributed to (1) NY Winters...salt..salt..salt. (2) My Neglect
(and the PO's neglect). 

First the Front Wheels were so overtorqued they broke three sockets
(including one Mac Impact wrench socket). Then, the right rear caliper
piston looked badly pitted. But, in order for me to get home we had no
choice to attempt a rebuild anyway (with the promise that the caliper
would be replaced). The next problem was that the Right rear brake line
was rusted together tightly. That took a very long time to free (and I
think a testimony to Igor for he was able to free it after about an hour
of gently manipulating it). 

Then I rounded the Carrier bracket bolt on the LF of the car. Then, the
darned thing wouldn't bleed properly. We had all sorts of foaming and
bubbling going on. Eventually, at 11:30 or so I started driving home. 

That's right, Igor spent almost 12 hours helping a friend rebuild his
brakes. Naturally, part of that guidance was a stern lecture on flushing
the brake fluid, on NOT ignoring your brakes, and on using cheapy places
to do brake work. But I also learned how to rebuild the calipers, and
how to properly do a brake job. Unfortunatey, some of the problems
resulted in us not being able to finish the job 100%, but Igor got my
car back together well enough for me to go home. There was serious doubt
in both of our minds whether I would be driving my 200q home or not. 

My carrier guides need new boots. The rounded front carrier bolt, and
the strange bleeding problem. 

So..thus far completed.

1. New SS lines all the way around
2. Rear Calipers rebuilt and functioning, including formerly stuck
e-brake arms. 
3. New Rear Disks and Pads.

Saga continues this week:

1. Install new Front Rotors and Pads (after getting that rounded bolt
out)
2. Pressure Bleed system
3. New Boots for Guides all the way around.
4. New Bleeder Valves all the way around 
5. Replace bad wheel bolt (ruined by me previously).


Lessons Learned (pay attention)

1. Always always always use a torque wrench on the wheels. Watch your
shop do it to be sure.
2. Flush your brake system at least every 2 years.
3. Depending on age/condition, a rear rebuild may not be a smart
decision.
Although we were able to free the e-brake arm without using a Stiffer
spring from a European Ford Granada, one of the pistons didn't look very
good. I'll be checking it often for leaks.
4. Replace your stock rubber brake lines after 10 years. Just do it.
Mine were within 2 weeks of failure. Go SS, but make sure you buy the
proper lengths. Some of the kits may be too short.  Mine cost $88.00
delivered Red Label.
5. Never apply massive toqure to a socket that isn't flush with the bolt
(my fault).
6. Having a pressure bleeder on hand may make bleeding much easier.
7. Tap the caliper with a hammer to get air bubbles moving.
8. Never ever let the cheapie chain store places touch your brakes.
9. A penny saved is not always a dollar earned when it comes to car
maintenance. 
10. Have a Quattro-repair buddy on speed dial for emergency advice. 

Favorite Quote of the experience:
" Eff it, lets just cut the damn thing! What do you think?" -I.K. 
:) 
(note: quote taken out of context).


Public Thanks to Igor for putting up with my incompetence and lack of
experience. I'm not sure if the experience soured him (for he had
alloted about 3-4 hours for the entire job), but it was a worthwhile
lesson for me. I appreciated it greatly. (Especially the patience). I
think you may have filled your "good deed quota" for a long time. :)

Look for an update of the completion of the project. We documented the
rebuild very well, so there may soon be a page that you can view on it. 
Igor, the list may appreciate your comments as well. 

-Osman Parvez
89 200q 177K
Albany, NY