Gerrard JTD has just about survived his annual brush with Doctor Death the MOT man.. which was amazing given the amount of soot that came out the back, during the smoke test.

But he didn't get away without the Grim Reaper having a nibble. Failed on the rear parking brake (both sides ****e, basically).

I'm going to fit new handbrake cables (needed) and new (or refurb'd) calipers since I don't have time/faith to dismantle and clean up my old ones..

Assuming the new calipers arrive wound out to more or less where they need to be... is there a special technique for setting the handbrake?

I will wind the calipers back, in the rotational direction of the wheel that each one is braking, just enough to get them to fit over the pads... then once tightened up, I'll pump the brakes a few hundred times, then finally attach the cables and tension them up.

Would that do it?


Ta.



Ralf S.

New or reconditioned calipers are usually supplied with the pistons fully retracted, however you may need to turn them slightly to align the two cut-outs on the face of each piston. They need to be horizontal to allow the pads to locate correctly.

Once the new cables, pads and calipers are fitted, press the brake pedal several times with the engine running, then adjust the swivel yoke at the back of the centre console so that both rear wheels are locked with 5 clicks of the handbrake lever ratchet.
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Davren said:

you may need to turn them slightly to align the two cut-outs on the face of each piston. They need to be horizontal to allow the pads to locate correctly.

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Today I learned the reason my handbrake is ****. Thanks Davren

Minus8 said:

Today I learned the reason my handbrake is ****. Thanks Davren

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Not aligning the piston cut-outs won't have any effect on the handbrake. If they were out of alignment, you wouldn't have been able to get the pads into the caliper.
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Davren said:

Not aligning the piston cut-outs won't have any effect on the handbrake. If they were out of alignment, you wouldn't have been able to get the pads into the caliper.
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Today I learned that my pistons have stayed in alignment through nothing but ignorance and luck.

Fixed!

I fitted/adjusted new calipers and pads.. and fitted a new cable on the right hand side.. so Gerrard dodged the Grim Reaper for another year..

On the other hand, the left hand hand-brake cable I received at the same time was too short, by about 13cm.

I ordered/received a Quentin Hazel part - QHABC3633 - which is apparently compatible with the Fiat part number (ePer via my chassis number) 51702642 .... but the cable is just too short.

The package is marked (by hand) "146" which is coincidentally near-enough the length of the outer cable (between ferrules). Other sellers on fleabay show that QHABC3633 is apparently 159cm long .. which is the missing extra length I need.

I'm vexed whether QHABC3633 is what I need and the part I have is something else, OR whether QHABC3633 is always 146cm long and so is not actually compatible, even though they say it is, and even though other sellers state the length as 159 (inner cable is 170 ish).

There's only one other handbrake cable listed for a 5 doors Stilo Active. A 2003 spec' is part number 46819335 (my car is January 2004 so might have been built with a 46809335.... which may be longer). But that doesn't explain why a QH cable is listed as 159cm and a substitute for 51702642 (ePer).. which would be correct for me.

What's going on then?


>> EDIT: One seller is quoting that QHABC3633 is compatible with both 46819335 AND 51702642.. and is 159cm long. Not sure if that helps..


Ralf S.

A lot of online sellers (especially on eBay) don't give accurate alternative part numbers for the item(s) they list. My guess is that they list as many alternative part numbers as they can find, just to get you to their listing (via a search for any of those numbers) just to make a sale. You buy the part, then discover it's wrong and send it back for the correct part..... They've got the sale, but you've been inconvenienced. I always do a a lot of my own research from ePER and aftermarket manufacturer parts catalogues before buying anything from these sellers.

Best way I find is to search ePER using your VIN, then cross reference the Fiat part number in aftermarket catalogues to get their part number. Using your VIN in ePER will highlight the part number(s) fitted to your car, and grey out numbers that are not fitted. That's a bit difficult in this case though, because ePER shows 4 part numbers (LH & RH for early cars and LH & RH for later cars), whereas the QH catalogue only shows three numbers and doesn't say which side one of them is for. It's not mentioned whether the lengths quoted by QH are for the inner or outer part of the cable.

BC3974 RH 1669mm.
BC3633 LH 1785mm.
BC3632 ?? 1645mm.
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Ralf S. said:

>> EDIT: One seller is quoting that QHABC3633 is compatible with both 46819335 AND 51702642.. and is 159cm long. Not sure if that helps. Ralf S.

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46819335 and 51702642 are the early and late part numbers for the left cable. The change or modification reason is shown on ePER as "New brake and handbrake tubes on rear suspension". Your guess is as good as mine as to what that means..... Changed the size of the cable mounting clip on the rear axle perhaps.
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Yes.. I think the cable I have is just the wrong cable but in the right packet.

ePer quotes the Fiat part 51702642 for my chassis number and this number seems to be interchangeable with 46819335 (according to QH in that table, and others.. but not according to ePer).

But if BC3633 is really 1785mm long, then it is the longest cable available .. but the cable I received is too short.. which is why I suspect that it can't be the correct cable.

Fittings are correct though. I bet it fits some other Fiat/Alfa.

1785mm is the inner cable length. The cable I received measures 1460mm (outer sheath) whereas I have seen BC3633 also listed as "1590/1785".... suggesting that I need a 1590mm outer sheath. The closest I could get it (pulled tight) was around 100cm too short.. so 1590mm would be a perfect fit.

The seller is investigating. I've sent them off to measure the length of another cable.... I'm just curious now.

Ralf S.

Just as an update in case it's useful.. a new cable (exactly the same packet as my previous one) was the correct length and fitted perfectly.

The "too short" cable wasn't the cable that the packet said it was (still unknown to this day)... so "the wrong part in the correct packet".


Ralf S.