Join Date: Apr 2000
Location: Auckland, New Zealand
How to: E21 rear brake upgrade for 02s
As promised in another thread, here is a "How to" by someone who was learning as they went. The drum part is incredibly simple. The handbrake cables were less so.
This picture is the most important - it is the "finished" article and shows all the major bits:
1) Loosen rear wheel nuts
2) Jack up back of car and support safely on jack stands
3) Remove wheels
4) Remove cotter pin from castelated (sp?) axle nut
5) Remove castelated nut using breaker bar and 36mm socket
- this is not as easy as it sounds!!
- I put the wheels back on, lowered the car again, put the 36mm socket on a 1/2" breaker bar, then used my jack handle over the bar to get about 3' of leverage. I did wonder if the bar was going to break... but it was fine
6) Take off drum
7) Pull off hub
8) Remove shoes, remove wheel cylinder, disconnect handbrake cable, remove back plate
9) Put E21 bits on:
- backing plate
- those retaining clip things on the side
- wheel cylinders
10) Reconnect handbrake (easier without hub on) - hopefully the 02 ones will have stretched enough to be ok
11) Put 02 hub back on
12) Do up castellated nut to something like 217ft lb (I used my full weight about 18" out on my bar and am hoping for the best...)
13) Put cotter pin back in
14) Drums on, set and bleed brakes and set handbrake
15) Road test
The tricky bit is the handbrake cable - the 02 ones will be slightly too short unless stretched.
I got E21 ones (living in New Zealand I get what I can). Apparently 02 Turbo ones are the perfect length. As a direct bolt in, the E21 ones are too short, so I had to trim (using my new Dremel ) about 30mm from each of the tubes the handbrake cable slides into on the body.
Hard to explain, but easy to figure out when you think about what is needed. I would suggest cutting off less rather than more...
E21 cables are a bit long, and I had to route them differently:
The red line approximates where the 02 cables would have gone originally.
So - what did I miss????
1975 911S (in bits)
1969 911T (goes, but need fettling)
1973 BMW 2002tii (in bits, now with turbo)
10-21-2002, 08:02 PM