UKPOC forums

Kit wrote: ↑

Mon Jul 05, 2021 9:28 pm

Do you mean
Worm Gear

Kit

Yes, predictive text!

That 'Allen ' cap-head screw is held in place by an internal circlip which is an absolute b..............d to remove UNLESS you have some very special
pliers. If it came out , without you removing that circlip THAT is why you cannot adjust your brakes.
NO circlip , no worky.

jrh wrote: ↑

Mon Jul 05, 2021 11:19 pm

That 'Allen ' cap-head screw is held in place by an internal circlip which is an absolute b..............d to remove UNLESS you have some very special
pliers. If it came out , without you removing that circlip THAT is why you cannot adjust your brakes.
NO circlip , no worky.

John, I think we may be talking about different things here, the allen key type adjuster that is accessed via the opening after removing the 12mm bolt, will come out, I have done it many times. The worm drive is held in with a circlip and is as you say a bugger to remove. plus you have to remove the piston first.
There is NO circlip on the adjuster

I accept your explanation Trevor , just wish I had not given all my spares away !

It's the Allan key adjuster at the back, sorry for not being more clear. If I apply moderate pressure to the piston face It then engages - and I can wind the piston to extend. It doesn't retract though. Engaging the handbrake lever doesn't move the piston either.

I bought them 'brand new' off eBay for £50 per caliper from gear-maxx, but I'm guessing their reconditioned. I've tried the 'old' adjusters in them and they 'work' as in extend when piston pressed, but still no rewind. The 'new' adjusters work perfectly in the old calipers too. It's a bonkers design.

that sounds like there is an issue with the worm gear, but as you say, seems a bit strange that both are faulty?

Where are you based?

Woah , stop.
Ford Workshop Manual , Rear Brake Caliper page 06-04-10 , exploded view. Perfect.
Item 10 is the adjusting screw with the snap-ring/circlip to hold it in place.
Item 10 has a 'gear tooth' which engages with Item 2 , the 'Allen caphead ' adjuster which, like you say 'falls out' without restraint.
The mad genus is the mechanism to push Item 10 !
BUT the snap ring/circlip MUST be there , for the brake to work.

Dundee in Scotland.

Could you post a picture of the exploded view?

It's the craziest design ever.

Picture

Is it easy enough to remove the piston? I've got one fully extended - I'm not sure if it'll help, but the guy isn't responding and I really want this done.