KIMI 3 - 1984 Series 3

[Casey]

So, with the brake hydraulic system refresh completed, I took the car in for it's MOT today.

Yippee, it passed with no advisories -

I really must use the car more next year. I've only done 538 miles this year

Having said that, it would have been more than twice that mileage this year, had she not let me down at the 11th hour with a clutch slave failure, meaning I had to take my RX-8 to the 55th Rotary Anniversary bash at JDM Combe (++).

[Threesevens]

good stuff Malcolm. No more excuses

[Casey]

Although my car passed the MOT, the tester did mention a slight drag on both the front brakes, so I thought I should check it out. I had, not long ago, cleaned and re-greased (Ceratec) the sliders, so, unsurprisingly, that wasn't the issue. Nor was it a hydraulic issue. The pads were also freely sliding on the end clips and the "Z" spring was in position correctly. However, the pistons were not retracting freely, so I decided to remove the driver side caliper first to take a look. Before disconnecting the hydraulic line, I used the brake system to push out the piston into a block of wood, having discovered from experience, this is the best way to get the piston out.

The caliper needed some TLC!

Driver side brake piston caliper , before cleaning.jpg (64.82 KiB) Viewed 12619 times

The piston seal and rubber boot were in excellent condition, but I have a new set, so will use those on re-assembly.

Driver side brake piston, after cleaning 2.jpg (55.01 KiB) Viewed 12619 times

The inner bore was fine, and so was the piston, but I couldn't slide the piston back in as rust had accumulated around the bore outside the piston seal. Here I have removed the piston seal and started to remove the rust. Once finished, without the seal replaced, the piston slid freely in and out.

Driver side brake piston caliper bore.jpg (76.29 KiB) Viewed 12619 times

I removed all the rust I could, degreased the caliper and gave it two coats of Hammerite smooth silver. Nearly ready to re-assemble, just waiting for the Hammerite to cure - it still seems a little soft and tacky after 24 hours

Driver side brake caliper kit.jpg (126.95 KiB) Viewed 12619 times

[ian65]

nice work, it's usually rust under the piston seal what makes it stick...... not the most enjoyable job to do but strangely satisfying whey they are all done and finished.

[Casey]

Passenger side front caliper refurb in progress....

20221124_153222.jpg (144.94 KiB) Viewed 12549 times

20221126_175934.jpg (134.24 KiB) Viewed 12549 times

[DKWW2000]

Good work Malcolm, that is very shiny silver paint Do you cover it with lacquer?

[Casey]

Hi Pete. No, that's just the completion of cleaning as much rust as possible from the steel - no paint yet applied. Next stage is degrease, then two coats of Hammerite smooth silver (see earlier photo of completed driver side refurb'ed caliper).

[Casey]

Both front calipers now reinstalled and system bled. Ready for a test drive today, if roads are dry.

Passenger caliper with 2 coats of hammerite and new seals fitted.

20221130_115357.jpg (108.73 KiB) Viewed 12514 times

[Threesevens]

Excellent work again Malcolm!

[Casey]

Brakes all good, with much improved pedal feel now (not a patch on the RX-8 though . There is a very slight pull to the left on an emergency stop with full front lock up, but nothing serious.

I went for a spirited drive with some heavy braking, parked up and immediately checked the disk temps with an IR gun. Both axle pairs had very even temps with the front pair higher than the rear, so all good there. Certainly no evidence now of disc dragging either