Hi Guys,

I have take my Stilo to my Uncles garage for him to put a new set of Disc's and pads all round and he appears to be struggling to get the rear caliper to wind in on the drivers side of the car. He has removed the old disc and pads and had used the specific tool for winding them in. The tool seemed to struggle to wind it in and after getting about half way home would not wind in any further, so then he unwound it again and it then got stuck and would not turn at all. He then used some brute force and managed to get it to wind in, but will now only wind in 1/3 of the way.

I really don't want to be spending in excess of £290 on a new rear caliper any suggestions on how to get the caliper to wind in.

NB! The brakes were all working fine before this work was carried out, pulling up correctly and hand brake working correctly, just big lips on disc's and pads reaching there limits as dash board warning light came on to inform me.

Many thanks for your time,

Warren

re: Problem with rear caliper (changing & pads) and now have rattle

turn calliper piston in the other way

re: Problem with rear caliper (changing & pads) and now have rattle

Are you (or your uncle) aware that the lefthand and righthand rear calipers wind back in opposite directions?

I suspect that if you've attempted to wind the piston out of the caliper, the triple screw arrangement that operates the handbrake and auto adjustment of the caliper is now misaligned causing it to sieze.

re: Problem with rear caliper (changing & pads) and now have rattle

Hi T14086 and Davren,

Well at the time when he tried to wind in the calipers no, but since now looking I am, have just sent him an email to let him know. So Davren, the actual caliper has a 3 screw setup inside it and if you wind it the wrong way it's time for a new caliper then I take it. It cannot be wound back in . Is it possible to take the caliper apart do you know and line them back up once more?

Thanks for the v. swift response chaps,

Warren

re: Problem with rear caliper (changing & pads) and now have rattle

I've only ever taken one rear caliper apart (foolishly) and never managed to get it back together again.

re: Problem with rear caliper (changing & pads) and now have rattle

Bit late in the day perhaps

but this thread shows the cheap tool that could've been used

https://www.fiatforum.com/stilo/85765-rear-brake-caliper-wind-back-tool.html

re: Problem with rear caliper (changing & pads) and now have rattle

Thanks Darven, Argonought, we used a universal tool to trun the caliper in, which looks like a cork screw and comes with different attachement plates that fit the calipers and comes with a left and right hand thread.

So it looks like if the Caliper has been unwound too much I am going to have to purchase a new one, does anyone know if Lucas calipers are any cop, as the fiat component is over £300.

re: Problem with rear caliper (changing & pads) and now have rattle

Lucas callipers are reconditioned to a high standard and their new ones are often fitted as origanal equipment by manufacturers.

re: Problem with rear caliper (changing & pads) and now have rattle

Budweg calipers from here cheap as chips..


http://www.fiat.car-brakes.co.uk/

re: Problem with rear caliper (changing & pads) and now have rattle

Thanks guys for all the input, we managed to get the calipers to free off and wind in by adding lubricant under the rubber boots and placing them in vices and hey presto caliper retracted and all is now well, or so it would seem. Now have a new issue, since having the brakes changed and brand new front tyres fitted, im getting a rattling noise from the front end of the car over rough surfaces, it sounds slightly metalic? my uncle suspected drop links and the anti roll bar, but could not feel any play in them. Is there anything else that could cause this sort of noise. Car appears to drive perfectly, no wandering or play anywhere. Had the MOT inspector go over it and he couldn't identify anything wrong?

He has ordered some drop links from his supplier and is planning to fit them this sunday, if the problem is still present what else could it be. All the engine mounts and wish bone joints look good so a bit at a loss here.

Many thanks once again,

Warren

re: Problem with rear caliper (changing & pads) and now have rattle

Most likely drop links. Surprised MOT tester didn't spot them though. Have a look in Stilo Guides for some useful tips re droplink replacement and diagnosing front end noises. They're cheap enough and quick to replace if you're in any doubt

re: Problem with rear caliper (changing & pads) and now have rattle

Thanks deckchair, yeah it's a weird one, there doesn't appear to be any play in them at all, however I have just popped to tesco and there is now a rattle coming from the rear of the car as well as the front, this was not present before the rear disc's and pad's were changed. I doubt its dodgy stuff though because I've used Lockheed pads and AC Del co disc's all round so the better quality spurious stuff.

Is there anything that can cause the rattle with regards to the actual disc's/pads being changed??

Cheers fellas,

Warren

re: Problem with rear caliper (changing & pads) and now have rattle

Anti rattle sprngs come to mind.

The pads need to fit into the anti rattle springs properly but it's difficult to see how anyone could get that wrong

re: Problem with rear caliper (changing & pads) and now have rattle

Hi again,

i thought it could be that but the rattle is present even when i actually drive whist feathering the brakes so am totalld it be the faces of the pads rattling against the caliper?

re: Problem with rear caliper (changing & pads) and now have rattle

Pads can rattle against the disc but as you had problems with the brake handbrake adjuster screw i wonder if you have a problem there. Does the handbrake feel right? Have you put the footbrake on hard and brought up the handbrake self adjusting mechanism by continuous application of handbrake?

re: Problem with rear caliper (changing & pads) and now have rattle

Hi Deckchair, yes I have done that but the rattle is still there, I am wondering now if it has somthing to do with the tracking, I have tried applying the brakes on a rough road and the rattle is still present. I used to get creaks coming from the front end over speedbumps and that seems to have stopped so I am wondering if it's somthing to do with the tracking adjustment that has been made. The car has been scrubbing off tyres as well, I only got about 8k out of the front tyres last time so I'm not 100% sure if it's a suspension fault that is now only showing up since the tracking and front tyres has been changed.

I had a look at the pads to make sure that my uncle has put the clips in and they are all present so dont think it's to do with pads moving.

I have ordered the drop links for the front end and they are going to be changed saturday, as I have read on the forum that it can cause a metalic rattle. Odd thing is though there doesn't seem to be any play in them. The car is driving fine, not pulling over and the brakes pull up fine.

Does anyone know if there is a suspension fault that causes these symptoms other than the drop links?

re: Problem with rear caliper (changing & pads) and now have rattle

Tracking will never cause rattling. Scrubbing off tyres though means your alignment is bad or there is other wear in the front suspension (track rod ends, lower wishbone etc). A lot of garages used to use the wrong settings for Stilos and there were loads of reports of bad scrubbing in the early days

You could do a visual steering alignment check (see Stilo Guides). My tyres have always run down straight and true and I've never visited a steering alignment shop with it

If the rattling stops when you apply the brakes then it won't be the anti ratle springs. As your uncle had a lot of stuff disconnected then it could be anything that hasn't been put back correctly

Drop links don't really have much play in them when they wear out, they just rattle internally, they're not like other ball joints as they dont take very heavy loads. Again, look in the Stilo Giudes on drop links for diagnosing other rattles and their symptoms

Creaks on speed bumps are usually the top suspension mounts

re: Problem with rear caliper (changing & pads) and now have rattle

Hi Deckchair,

Yes I have done that, the calipers on the rear screwed in fine once they were unceased and wound in. I dont think it's brake related as it seems to occur even when the brakes are on over bumpy ground, it's either going to drop links or some sort of suspension fault. I am only thinking this because the car was on a ramp for 3 days with the suspension left fully extended so maybe when the suspension has dropped to it's full extent a failed bush or drop link may now be showing as a result. Also there doesn't appear to be rattling coming from the rear of the car, just think it was my eye's playing tricks on me, it seems to be from the front.

Will get the drop links slapped on and let you know how it goes. I hope it's not suspension problems though tbh as I have heard it can be a v. expensive businsess with the stilo.

re: Problem with rear caliper (changing & pads) and now have rattle

Hey Deckchair,

It was the drop links after all, the anti roll bar was rattling, swapped them out this afternoon and it's now quiet at a mouse, thank you all for your input on this one. I am so happy that my Stilo is back to it's usual self, as despite it costing me almost £1600 in repairs over the past 3 years I love it to bits.

Many thanks,

Warren

re: Problem with rear caliper (changing & pads) and now have rattle

Great stuff. Sounds like a bit of a death rattle when they're worn out but a very quick job to change them. Glad it's fixed