ZX Rear Disc Replacement HELP NEEDED PLEASE

Gnerk · Unread post by **Gnerk** » 12 Nov 2006, 18:59

Hi all,

I attempted to change the rear discs and pads on my 94L ZX Td Volcane yesterday, and had a bit of time with it. 7 hours just to put the car back in a worse state than it was when I started...!

Got the discs and pads off no problem (surpised as I expected everything to be seized to kingdom come). However, I found that I could get the brake caliper piston back in (tried my usual trick of 'gently' pushing back with a G-cramp, no dice).

I think the caliper is probably seized, but I wonder if I'm missing something. I have a Haynes manual somewhere, but can't find it presently, and have almost no experience with rear disc brakes, especially those with that kind of handbrake mechanism (my old Subaru used to have a kind of disc/drum arrangment on the back).

Anyone one know if I need to back off the handbrake, or free off some kind of auto adjuster to get the piston to move again? The piston had definitely moved 'cos in my b*ggering about I managed to get it to come further out than it was when I started (hence preventing me from re-fitting the old brakes to keep the car drivable - ho hum).

I'm obviously cr@p. Please help me

- Ian.

nick · Unread post by **nick** » 12 Nov 2006, 19:13

Assuming they're similar to the Xsara rear callipers the piston screws in clockwise to back it off to accommodate new pads. There should be notches in the face of the piston to allow something to be engaged in it to turn it.

Gnerk · Unread post by **Gnerk** » 12 Nov 2006, 20:38

Nick,

D'OH

A VERY HEARTFELT THANK YOU FOR THIS.

There are indeed notches on the face of the caliper. Turning the piston would seem to be the way forward then.

Gotta learn some when.

Thanks,

- Ian.

nick · Unread post by **nick** » 12 Nov 2006, 20:59

No probs! I changed the rear pads on my Xsara last weekend & thought they would probably be the same on a ZX.

The front calipers on Xantias & BXs are also like this (due to having front handbrakes). When my dad first bought a Xantia he spent an entire weekend trying to force the caliper pistons back with progressively larger & larger G cramps....

Unread post by **Peter.N.** » 12 Nov 2006, 22:45

The piston has a very fine thread, you will think you are never going to be able to screw it in. If you can make or find something that will enable you to turn it at least one turn at a time it will speed things up considerably.

np · Unread post by np » 12 Nov 2006, 22:55

I found a wood chisel was best for winding the pistons in on my Xantia.Cant remember which size now,but i have loads anyway.
But it fits in the slots a treat.

Unread post by **Peter.N.** » 12 Nov 2006, 23:12

... and useful for rebating afterwards!

jeremy · Unread post by **jeremy** » 13 Nov 2006, 00:11

I think the slots are meant to fit the shaft of a square shafted mechanics screwdriver.

You'll probably find the handbrake cables on your ZX are siezed. They are not very expensive from GSF and places but seem to be disposable.

Unread post by **RichardW** » 13 Nov 2006, 12:31

If you've really wellied it with the G cramp, you may find you have wrecked the mechanism, and new calipers will be called for.....

H/brake cables are easy enough - but I had trouble getting the ferrule out of the caliper - I had to make a special drift, and heat the caliper up to get it out!

Gnerk · Unread post by **Gnerk** » 13 Nov 2006, 21:17

Thanks to all for the advice.

I am not a man of large build so hopefully I haven't wellied it with the G-cramp too much; although I thank my stars that I didn't get the BFH (Big F Hammer) out in a fit of pique. I do get so vexed when things misbehave.

I'll post again when I've had another go. No light in the garage, so waiting for ebay to deliver me a 12v inspection lamp to have another go mid week.

Cheers all,

Ian.

jeremy · Unread post by **jeremy** » 13 Nov 2006, 22:03

Haynes Manual in english (petrol I know) available for download here.

Brakes are probably largely the same.

http://citroeny.cz/servis/servis.htm

Gnerk · Unread post by **Gnerk** » 13 Nov 2006, 22:18

That'll help!

Moved to Worthing 3 months ago from a 3 bed semi into a 2 bed flat. I have some books...somewhere...

Gnerk · Unread post by **Gnerk** » 24 Nov 2006, 21:50

What up, dudes.

Fixed rear brakes with help from you all. Most appreciated.

Caliper reaction frame was badly stiff (but not piston) - sorted quickly by a squeeze of WD under the rubber dust guards + a little soak time.

Anyone know if someone supplies these dust guards as spares - I have some torn ones on the other side...

Otherwise, all okay.

Cheers,

Ian.

jeremy · Unread post by **jeremy** » 24 Nov 2006, 22:10

A very similar caliper is used on the front of the BX and may be used on many other cars.

You probably have a local brake specialist or two and you will find they can provide all sorts of small parts which you would have thought were unobtainable. Good old Yellow Pages may be a good starting point.

rossnunn · Unread post by **rossnunn** » 25 Nov 2006, 15:15

http://www.biggred.co.uk/

they do all the service kits for both front & rear calipers. 8)