Front Brakes Replacement With the front suspension rebuilt, the next phase of the restoration of the 1969 Alfa is the replacement of the front brake components. This particular brake system employs a dual-piston front caliper that provides the car with enhanced braking performance and stopping power. The complete front brake overhaul includes replacement of the brake hoses, calipers and brake pads. Following are highlights of the front brake system disassembly: - Remove the hubcap to access the lug nuts in order to remove the wheel and tire (figure A).
- Carefully loosen the brake line connections and disconnect the brake lines (figure B). Use caution during this procedure, as there is likely corrosion and debris, and the line connections may be fragile. Also be aware that, even if the vehicle has been stored for a long period of time, there is still likely to be fluid in the liens. Take note of how the lines come apart in order to make re-assembly easier.
- Pry the dust-cap from the center of the rotor assembly (figure C).
- Wipe away the grease so that you can access the cotter pin and carefully remove it using a pair of pliers (figure D).
- To remove the rotor assembly remove the spindle nut, take out the outer bearing, put the spindle nut back on and use the spindle nut to drive out the inner bearing and wheel seal (figure E).
- The final step in the disassembly of the brake is the removal of the dust shield (figure F). If the dust shield is in good shape, save if for refurbishment. This is one part that can likely be cleaned up in a parts washer, re-surfaced and painted for use in the restored braking system.
Following are the steps in the front brake system re-assembly . - Install the new or refurbished dust shield (figure G). This is a simple nut-and-bolt installation, but because it mounts onto the steering knuckle and spindle assembly it may require bolts of different lengths.
- The dust-shield fastener also serves to bolt the brake line assembly to the back of the spindle (figure H), and a separate bolt fastens it to the tie-rod.
- Assemble the brake line, connecting the rubber hose from the caliper to the steel line at the chassis. Carefully tighten the line connection at the bracket, then tighten the top of the steel line to the top of the rubber hose (figure I).
- With the wheel bearings cleaned, inspected and repacked, and the inner seal replaced on the inner bearing (figure J), you can then install the rotor, tighten down the spindle nut, and adjust the tension.
- Re-install the cotter pin to hold the rotor assembly secure (figure K).
- Re-install the dust-cap (figure L), tapping it carefully with a hammer to make certain that it is seated all the way. The dust-cap helps prevent water from getting into the rotor assembly while driving.
- Once the rotor is installed, it can be oriented (figure M) for installation of the brake caliper.
- With the brake caliper pre-loaded with brake pads, fit the steel line into the caliper before mounting it to simplify installation, then bolt the caliper in place (figure N).
- Once the caliper is mounted, do a final tightening on the brake line (figure O) to complete the assembly.
- Once the brake restoration and assembly is complete (figure P), check the condition of the rotors using a rotor gauge.
In the segment that follows, the brake master cylinder and upper servos are replaced.
RESOURCES :
Alfa Romeo Owner's Bible: A Hands-On Guide to Getting the Most from Your Alfa
Model: 0837607078
Author: Pat Braden
Order this book from Amazon.com
Bentley Publishers
Alfa Romeo Spider: The Complete Story
Model: 1861261225
Author: John Tipler
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Crowood Press
Original Alfa Romeo Spider (Bay View Original Series)
Model: 0760311625
Author: Chris Rees, James Mann
Order this book from Amazon.com
Motorbooks International (MBI Publishing)
Essential Alfa Romeo Guilia & Giulietta Coupes & Spiders: The Cars and Their Story 1954-95
Model: 1870979591
Author: David Hodges
Order this book from Amazon.com
Motorbooks International (MBI Publishing)
Alfa Romeo: The Spirit of Milan
Model: 0750919582
Author: David G. Styles
Order this book from Amazon.com
Sutton Publishing
Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners ...
Model: 1557881944
Author: Jim Richardson
Order this book from Amazon.com
H.P. Books
Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
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Haynes Publishing
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