309 handbrake cables

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pazz
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Joined: 31 Oct 2005, 22:35
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309 handbrake cables

Post by pazz »

I need to replace the handbrake cables on my 309 (1.6 with rear drum brakes). I remember from doing this job on my previous 309 that it was difficult to fit the end of the outer cable into the brake backplate. The cable ends with a serrated steel piece which is an interference fit in the hole in the backplate. There isn't much surface on the serrated part to apply force with a drift, so it is very easy to damage this part. Also the backplate is quite thin and flexible, which makes it difficult to hammer anything into it. Last time I resorted to filing the serrated part down slightly to make it easier to fit, but this was a bad idea, as it made the outer cable prone to being pulled out of the hole due to suspension movement. Any suggestions?
1993 309GLi Auto 145K
1993 405GLi Auto Estate 218K
504

Post by 504 »

This sounds like exactly the same kind of set up used on my 504 saloon. I used a screw driver and hammer to tap the metal end in to the hole for a good fit. To get the old ones out I ad to use a punch.
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pazz
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Joined: 31 Oct 2005, 22:35
Location: United Kingdom
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Post by pazz »

Thanks for your reply. I tried using a screwdriver and hammer last time, but the screwdriver damaged the metal end piece.
1993 309GLi Auto 145K
1993 405GLi Auto Estate 218K
504

Post by 504 »

yes the metal is very soft, the only other thing would be to fashion some sort of punch from an old socket or likewise, chop a bit out with the grinder so it goes over and gives you something to hit.
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pazz
Posts: 23
Joined: 31 Oct 2005, 22:35
Location: United Kingdom
My Cars:

Post by pazz »

I think you're right - it would be worth making a special tool for this.
1993 309GLi Auto 145K
1993 405GLi Auto Estate 218K
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