Help Please... rebuilt calipers don't fit.

[dt-911]

Hello there,

It sucks to be asking for help in my first post... but guess I'm not alone!

Anyway, some time ago after finding me completely randomly on e-bay UK, a lovely (but slightly eroded) '85 Carrera Targa 3.2 has found it's way half way around the world to Australia. Since landing I have been slowly preparing her for compliance and registration down here in OZ...

Among other things I have recently rebuilt the calipers all round, replaced the rotors, hard and soft brake lines, and front wheel bearings (cheap and easy while it was all apart). The drama now is that I am at the near finishing point of putting the front calipers on and installing new pads, sensors and clips but the rebuilt calipers will not even go over the new rotors . The rears have gone on fine but the fronts seem to be a few mm too tight. Additionally, it seems like they will also not align to the bolt on points even if I can force them over the rotors.

As far as I can tell, the old front rotors were worn way lower than spec. as they were only about 18mm thick with much more wear on the inner side of both. I think I read somewhere that std spec is supposed to be 22-25mm, and the new rotors are 24-25mm (don't have a micrometer so that's measured with my old year 10 graphics steel ruler!). So I am thinking they should be right (?).

My questions are:
- is it possible that I need to get the new rotors machined to fit? They are drilled and slotted aftermarket ones, so I guess they could be the problem.
- has some PO shrunk the original calipers in someway to get bite on the undersized worn rotors?
- Or, are the spacer blocks in the calipers available in varying sizes and I need a larger one?

I have limited knowledge of P Car tech so any advice on simple DIY fixing would be much appreciated.

HooRoo, Dave & the "Crusty Carrera"

['78 SC]

Sound like you have "A" calipers from an SC, which require 20mm rotors. Carreras came with "wide-A" calipers and use 24mm rotors. Maybe a previous owner swapped them out?

As you guessed, the difference is the spacer between the caliper halves. BTW, separating the caliper halves is not recommended because of issues getting correct seals and hardware.

Good luck.

[dt-911]

Thanks for the quick response Steve, appreciate your time.

If a PO did that change would it be considered a downgrade? What would be the purpose of stepping back to an earlier brake version? Is it even legal (generally) to run earlier version brakes? I am thinking someone may have done a dodgy on an unsuspecting PO and swapped so they got an upgrade? Funny thing about this car is it also has Turbo tie rods... could the two go together as a handling/performance upgrade of sorts? Lightening and stiffening the front end somewhat?

Anyway, I guess I am either up for some new rotors (again!) or some new calipers... Just looked at the ultra competitive (in OZ anyway) pelican parts & price list and calipers will cost approx. $700 once I add freight to OZ. Hoping a cheaper option may be possible... is anyone aware if the "wide a" spacers are available to buy anywhere?

Surely seperating and rebuilding is actually possible (although I understand not recommended)?

Again, appreciate the time.

Dave & the 'Crusty Carrera'

[KNS]

If you indeed have SC calipers on a Carrera then yes, that's a downgrade. I believe putting the thinner rotors will work and probably stop just fine, it might be difficult for the casual observer to tell the difference. You really do need to get the correct calipers on there though, spend a little extra and do it right. Keep your eye open in the classifieds here, I just saw some used Carrera calipers for sale not long ago.
Turbo tie rods are also an upgrade.

[dt-911]

Hello again, and thanks KNS,

I will definitely keep my eye's open for used parts in the marketplace here (already have been looking at pelican new and e-bay USA/UK/AUS) but I am just dumbfounded that there is nobody out there selling the "Wide A" spacers or perhaps a swap out - upgrade service. Especially given that there seems to be plenty of SC "A" version calipers around (on e-bay, etc.).

I wonder, are there other solutions I am not aware of being a relative newbie to the P brand? Or, is everyone out there just trying to sell us suckers some unnecessary, overpriced, upgrade package?

Does anyone in P virtual-land have any idea of where I could purchase "Wide A" spacers or a swap out - upgrade service? Surely somebody is catering for this need somewhere on the planet...

Any idea's/comment/direction much appreciated,

Dave & the "crusty carrera" - first photo below (I hope it works!).

[CruiseControl]

dt-911
I have a set of Carrera '86 Front Calipers available if you wish to head in that direction. Located in Brisbane. I will send a PM with email contact details.
Paul