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1969 Alfa Romeo: Rear Disc-Brake Replacement From "Classic Car Restoration" episode DCR-104

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Figure A Figure B Figure C Figure D Figure E Figure F Figure G

The rear disc-brakes on the Alfa Romeo Spider feature dual-piston brake calipers (figure A). As with any typical disc brake system, the brake rotor is positioned between the brake pads of the caliper (figure B). But with this braking system, when the brakes are applied, hydraulic pressure is applied to the rotor from both sides rather than just one side. This racing-engineered braking system provides the enhanced stopping power that is characteristic of this performance car.

Following are the major steps in the replacement of the Alfa's rear disc brakes.

• With the tire and wheel removed, begin by driving out and removing the pins that hold the brake caliper in position.

  
  

• Remove the brake pads.

  
  

• Loosen and disconnect the brake lines from the caliper (figure C). Some penetrating oil may help in loosening the lines if the old lines.

  
  

• Loosen the two bolts that secure the caliper to the rear axle, and carefully remove the caliper itself.

  
  

• Bag the caliper with all of its mounting hardware so that it can be turned in when purchasing a new caliper to avoid paying a core charge.

  
  Note: A core charge is a charge assessed on some new or rebuilt car parts that will be refunded upon the return of the parts being replaced.

  
  

• Spray some penetrating oil on the hold-down screws securing the rotor (figure D), and remove the screws.

  
  

• To remove the rotor, it may be necessary to carefully tap it from behind with a mallet.

  
  

• With the axle flange cleaned, a new rotor can be installed (figure E). Apply some anti-seize compound to the set-screws before installing them to secure the rotor.

  
  

• Position the new caliper (figure F), and install the mounting bolts, but don't tighten them all the way just yet.

  
  

• With the bolts loosely holding the caliper in place, attach the brake line (figure G) and begin tightening it.

  
  

• With the brake line secure, tighten the caliper mounting bolts.

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
Order this book from Amazon.com
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
Order this book from Amazon.com
Haynes Publishing