Alfa Romeo 164 S Brakes front

Brakes are important.

Enough money for 17 " rims ,tires,Brembo.

Spareparts.Get some new parts first. CHECH diameter of piston ,Caliper reneval kits INCLUDING new calipers , bolts sliding pins,pads brakefluid ,paint.   LOCTITE

 EBC brake pads green stuff 164.1

Caliper reneval kit for 54 mm piston , some cars have 57 mm pistons.
 This is where you find the number (164.26 )

                                                                                                                                                    164.2

Rustease , brake cleaner , brake grease
Tools 19 mm socket , breaker bar.
Jack ,stands.
Ringspanner 13 mm and 15 mm.
Steel brush.
Gloves,protective glasses.
Sledgehammer well you newer know.

Loosen wheelbolts , Jack up car ,APPLY EMERGENCY BREAKE Gear in drive remove bolts , remove wheel ,turn steering wheel so brakecaliper comes more out of wheelarch.

                                                                                         You never know when 400 Nm is not enough to loosen a bolt buy a long breaker bar                   164.3

That bolt is not good , it came of way too easy and the threads are missing
 I have to replace the hub too hence the missing hubnut
Torque 95 - 105 Nm.                                                                   164.4

There should have been a rotor retaining bolt or dolly 

Torque 6 - 13 Nm., 

                                                                                                                                                     164.5

Caliper securing bolt 13 mm head and sliding pin 15 mm head

164.6

Prize the caliper from the pads ,remove ABS wire from brakeline, brakeline from bracket . Pad wear indicator wire off.

                                                                        164.7                        ABS wire off  164.8

Secure the caliper to the strut spring  Sliding pins really stuck ! I didnt se that one coming.
Bracket off 19 mm socket breaker bar , if the wheel has been turned , brakeparts out there is room for the long breakerbar.

164.9                                                                                             Bracet off 19 mm socket     164.10                                                                                                            Torque 52 - 58 Nm.
                                                                                                     

Sliding pin boot of , WD40 and a lot of force to pull it off  that is not normal careful with the thin groove for the rubber boot
                                                                                                  164.11

Clean them , including the threads for the bolts ,this is where loctite will hold the caliper bolts in place when you brake a 4000 pound car from 100 mph to stop in 100 feet.

Sliding pins CLEAN 164.12                                                                                    Cleaning tools

Inspect the bracet where brake pads are in contact with them, you will notice that cleaning them is more easy when the bracet is off the car .Roting wirebrush is awesome, use protective glasses.

164.13

164.14

This is important, the pads have to be able to slide . Remove all rust , consider how long it will take to become rusty again and then decide to paint the bracket properly.

                                                            Closeup outer side of bracket 164.13

Bracket inner side 164.14

Degrease ,degrease again do it outside , or your lungs might fall out of your body . Bracket holes filled with something , you dont want paint on the threads remove the something while paint is still wet. 164.15                Final heat resistant paint                       164.16

Dry harden paint.

Continue on caliper, press brake pedal to unleash the Kraken piston.

164.17

So far the piston looks fairly good. There is dust and dirt under the dustboot its supposed to be on the outside only

Someone painted the caliper withe the boot on.

17 mm ringspanner onto hose nut

164.18

 11 mm ringspanner onto fixed hose this tool is a special one from Williams it gives you the benefit of more contact surface to the nut 164.19

The bracket is supposed to slide , but rust dirt and lack of patience plus the decision to buy replacement hoses made me cut the hose sorry , never done that before.

Bracket close up after removal of fixed line use WD 40 surprice , and a screwdriver.

164.20






164.21  Bracket and fixed hose
 cleaned degreased.

                            164.22 Painted

You can still scource these lines from e bay , Canada

BRAKE CALIPER GIRLING 54 MM PISTON SAVE YOUSELF SOME TROUBLE AND PRES THE PISTON OUT USING THE BRAKEPEDAL WHILE THE HOSE IS STILL ON.


164.23

Piston and dustboot of inner seal in place  ,
clean with circular movements
164.24




















Clean, use a microfiber cloth with a rough surface CLEAN GROOVES for caliper seal and dust boot properly, Clean inlet and vent for brakefluid, clean threads. Blow dust away.
                                                                                                              164.25

It actually says the piston diameter on the CLEAN  caliper                                                        164.26

Papertowel into all holes with threads and the piston chamber ,
Degrease paint heat resistant primer and the topcoat , here red.
remove papertowel while paint is wet or it gets stuck.

Brake caliper and bracket in the paintbox                                                                                      164.27

Dry harden clean grooves add new bleeder valves .The old one was stuck surprice....and did not look good after a mole grip had to be used. M 8 x 1,25 M means metric , 8 means 8 mm diameter and 1.25 refers to the type of threads that fits this thread gauge
                                                                                                                                                       164.28

Old bleeder valve will not fullfill its purpose

 of easy fit tightning and letting air out wheen needed

Torque 4 - 6 Nm.                                                                                164.29

Its time time to put it back, all of it .

164.30

 Piston seal first make absolutely shure with your fingertip that is is even all the way.
164.31

 164.32  Apply brakefluid to it, Alternatively grease , the kind that complies with brake fluid  lubricant.

Dustboot into the groove too, make shure using your fingertip that it is in the groove all the way around.

164.33              Dust boot.                                                                 164.34 lubricant

NO sharp instruments , these are for bikes , plastic                                                             164.35

Squeeeeese be shure that piston is centered and doesent tilt 

164.36

All the way in . 164.36

Pipe in 11 mm ringspanner   
Torque 8 - 10 Nm   164.37                       Bracket for flexible hose on 10 mm 164.38

Sliding pins with new boots and calipergrease renew that grease every time you fix the brakes

164.39

Enjoy this is going to work properly.

164.40                                                                             164.41

164.42

Got the new colored stainles steel hoses today get your 11 mm  and 17 mm ringspanner.
                                                                       Torque 8 - 10 Nm           164.43

Retaining clip in place in the groove on the brake hose.
                                                                                                              164.44

New sliding bolts on E - bay just too tempting.

                                                                      LOCTITE ON THE TREADS 164.45

Detail of the bolt securing the caliper to the bracket, thats where the loctite has to be.

That means, when you reuse the old bolts you have to clean and degrease them and then apply loctite.

Note the orientation of the rubber boot smallest opening towards head of bolt.Large opening towards the bracket.
Torque 31 - 38 Nm.                                                                                                     164.46

Time to disconnect the flexible hose Brush , clean,WD 40 , pull the clip that secures the hose assembly plus 11 and 17 mm ringspanner
164.47

Push the rigid line down through the bracket it gives you enough space for the tools
Torque 8 - 10 Nm.                                                                     164.48

A plastic valvecap fits perfectly , just push it on , it doesnt have to stay on the threads 164.49

Stops the drop.

The ABS connectors are shot , solution buy some 2 pinn weather proof connectors.


                                                                                                                                164.50

                                                 
                                                                                                             164.51
Tools needed.

 This is the end , now cutting theese of means point of no return.   KEEP TRACK OF THE WIRECOLOUR CODE AND THEIR POSITION IN THE CONNECTOR.

                                                                                                                                  164.52

Put the silicon seal onto the wire , then crimp the pin to the wire follow the instructions
                                                                                                                                                       164.53

 Pin and wire insulation is supposed to end up circular in shape use whatever tool gentley small steps , I ended up using the crimp tool , that you are not supposed to use for this step.

                                                                                                                               164.54

 Once the pins lock into the connector they really stay there !!!
                                                                                                                                                        164.55

 Ready for assembly , need the recieving connector to be changed too.

                                                                                                                                                   164.56

 
Brake assembly onto hub assembly , here out of the car. Left side of the car
                                                                                                                                                  164.57

Detail , lubricate here.

164.58

There 164.59.

Where brakepad and bracket touch.

164.60

More lovely pivtures
                                                                                                                                  164.61

ABS toothed ring detail
                                                                                                                                 164.62

Detail ABS wire in the brackets and UNDER the rigid brakeline

                                                                                                                                                      164.63

164.64

Hope to change the ABS sensor , well , rust in an iron cavity makes it smaller ......soooooooh.
Buy a new sensor before you try that , if you are lucky someone did actually grease that sensor part the last time they too it apart, chances are they did not.                                                               164.64

Remove abs sensor cable bracket , allen key , Turn hub ,tab very gently , perhaps a small socket instead.IF greased , it comes out intact.
ABS sensor , bracket164.65

Closer look , no it not supposed to look like this                                                             164.66

Thats why rust ( surpirced ...)                                                                                              164.67

Clean it a dremel with a tiny rotating sanding bit is perfect for this
164.68

Clean the threads for the allenbolt. Greese.
                                                                    New ABS sensor                                           164.69

Perfetto from Italy , ebay                                                                                                              164.70

William Lutken.



This looks nice too.
Waiting for Brembo Max Lott autoteile failed to box them right so they were lost , Carondo did exactly the same mistake . Now third attempt to get some Brembo Max.
I´ll be back.