Hi Folks, I have a bit if an odd issue with a  replacement NSR caliper fitted to my 55 reg Fab Vrs. (Purchased from a renowned ebay seller)  

The caliper fits perfectly and works as it should but the issue is that the angle of the brake hose prevents the top caliper mounting bolt from coming out due to the hose fouling the loosened bolt. There is no other position for this hose to be, where it bolts to the casting. 

The first pic is the new caliper showing the fouling hose and the 2nd picture is the OSR caliper showing plenty of clearance. 

The seller insists this caliper is correct and he has sold over 200 units with no issues.

Has anyone come across this problem before? Any thoughts appreciated. 

 

That's a weird one, it looks like the flexi's wrong for the caliper if anything. There's no chance the flexi's upside down is there? I'm wondering if the banjo's thicker on one side than the other. 

Hi Steve. The hose is in exactly the same position as it was on the original caliper and this was fine. I've taken a couple of measurements since posting and it appears the casting that the hose attached to is slightly taller. Very strange as everything else is perfect. I just wondered if anyone has encountered this before? Pics attached are new NSR caliper vs existing OSR.

Send the seller those pics and say you'd like one with the right measurements, please.

You do not need to remove the caliper slide bolt to service the brakes.

 

I appreciate that were you to want to remove it you would have to remove the brake hose banjo fitting but unless I have misunderstood, what is your problem?

@johnthomas99 where did you get them from. I have a couple waiting to be fitted myself 

2 hours ago, J.R. said:

You do not need to remove the caliper slide bolt to service the brakes.

 

I appreciate that were you to want to remove it you would have to remove the brake hose banjo fitting but unless I have misunderstood, what is your problem?

 

I my world, with these Lucas rear callipers, you do need to remove these 2 bolts to service the rear brakes, unless "servicing" is just spraying some brake cleaner in.

 

I was going to suggest that the copper sealing washers on the banjo bolt look to be too thick, but seeing the difference in the same measurement side to side in the pictures, what I was considering to be thicker washers, just pales into insignificance.

 

So far the worst thing that I have had when buying a re-manufactured rear Lucas calliper was what looked like a "garden shed" job of repairing a stripped bleed valve hole - I just handed that otherwise okay calliper back.

 

Edit:- this makes me think that I should take a look at the one I fitted a couple of months ago, seeing as the  fluid line was the bit I did last - I had filled up the calliper with fresh fluid before putting the fluid line back on - just to displace as much air as possible, as I just bleed it using a Mityvac hand pump after removing my sealed cap from the reservoir. 

 

Maybe it has a different size of piston, ie meant for another car, if so another reason to return it. I think that there were 34mm and 38mm versions of that model, and just maybe 41mm pistons. The pistons on my wife's 2015 VW Polo 1.2TSI were 38mm, I wasn't that trusting, I measured both piston sizes of the original calliper and the re-manufactured one. Plus I went over the new calliper with a digi calliper to check what I considered to be all relevant measurements.

Edited 21 May, 20242 yr by rum4mo

Can you not slacken the bolt and push in the sliding sleeve to disengage from it to remove the caliper?

 

From the photo I am fairly sure that I have worked on them and thats what I do if there is an obstruction.

 

Granted if the new pads come with new bolts and you want to use them.................................................

22 hours ago, Breezy_Pete said:

Send the seller those pics and say you'd like one with the right measurements, please.

I have done that today and they have agreed to refund me. I am looking to leave the caliper on now though, as it appears okay. It's just a pain when wanted to replace the pads etc.

20 hours ago, gav_is_con said:

@johnthomas99 where did you get them from. I have a couple waiting to be fitted myself 

It's an ebay seller. They have agreed to refund me today so I can't complaint really.

20 hours ago, rum4mo said:

 

I my world, with these Lucas rear callipers, you do need to remove these 2 bolts to service the rear brakes, unless "servicing" is just spraying some brake cleaner in.

 

I was going to suggest that the copper sealing washers on the banjo bolt look to be too thick, but seeing the difference in the same measurement side to side in the pictures, what I was considering to be thicker washers, just pales into insignificance.

 

So far the worst thing that I have had when buying a re-manufactured rear Lucas calliper was what looked like a "garden shed" job of repairing a stripped bleed valve hole - I just handed that otherwise okay calliper back.

 

Edit:- this makes me think that I should take a look at the one I fitted a couple of months ago, seeing as the  fluid line was the bit I did last - I had filled up the calliper with fresh fluid before putting the fluid line back on - just to displace as much air as possible, as I just bleed it using a Mityvac hand pump after removing my sealed cap from the reservoir. 

 

Maybe it has a different size of piston, ie meant for another car, if so another reason to return it. I think that there were 34mm and 38mm versions of that model, and just maybe 41mm pistons. The pistons on my wife's 2015 VW Polo 1.2TSI were 38mm, I wasn't that trusting, I measured both piston sizes of the original calliper and the re-manufactured one. Plus I went over the new calliper with a digi calliper to check what I considered to be all relevant measurements.

Yes, I normally remove the mounting bolts to replace the pads as normal. But I'm thinking there may be way round this so I can leave the caliper on as it appears to be fine other than the hose position.

A good point you raise re the piston size. I didn't think to measure it and perhaps I should have done. Something I'll need time look at...

8 hours ago, J.R. said:

Can you not slacken the bolt and push in the sliding sleeve to disengage from it to remove the caliper?

 

From the photo I am fairly sure that I have worked on them and thats what I do if there is an obstruction.

 

Granted if the new pads come with new bolts and you want to use them.................................................

That's a good shout. I may have enough room to free the mounting bolt from the thread and pull back the slider sleeve to release the caliper? I will have to attempt this. Thanks.

21 minutes ago, johnthomas99 said:

It's an ebay seller. They have agreed to refund me today so I can't complaint really.

I have a pair from SSL Autoparts eBay, were yours the same, so I can ask my mechanic to take a close look at this when fitting mine. I don’t have a vernier caliper to measure mine. 

7 minutes ago, gav_is_con said:

I have a pair from SSL Autoparts eBay, were yours the same, so I can ask my mechanic to take a close look at this when fitting mine. I don’t have a vernier caliper to measure mine. 

No, mine were from a different company. Just ask him to check the hose position before he fits it. I fitted others in the past and never had any trouble.

Just now, johnthomas99 said:

No, mine were from a different company. Just ask him to check the hose position before he fits it. I fitted others in the past and never had any trouble.

Thanks for that. I am in with a fighting chance they might be correct as they are genuine refurbished ones have Lucas type markings on them and auction lists for Fabia vRS and in a close shade of green.