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        General >> Problems >> Brake and airbag problems on cosworth
        
(Message started by: catalina on Aug 11^th, 2012, 10:15pm)

Title: Brake and airbag problems on cosworth
Post by catalina on Aug 11^th, 2012, 10:15pm

Can someone help with two problems please:

1. Handbrake has excess movement. I read that this is usually the result of corrosion on the adjuster system located in the centre of the brake piston. How can I check this and repair if necessary? Is it necessary to remove the complete caliper unit? If so, is it a careful diy job to dismantle and repair/replace the adjuster system?

I can't find any instuctions anywhere.

2. The airbag light to the left of dashboard flickers intermittently. I read that this is probably a dirty contact inside the steering wheel hub. How do you get into the hub? I've tried prising off the plastic airbag cover but this doesn't work and I am afraid of doing harm. Can anyone help please? Again, can't find any instructions.

Hope you can help.

Cheers, John

Title: Re: Brake and airbag problems on cosworth
Post by Simmo on Aug 12^th, 2012, 9:45am

The details of how to deal with the Airbag are Here (http://www.fordscorpio.co.uk/airbagmanual.htm). ;)

If you look in 'How to do things' (pages 3 and 4) there are links to this subject. One of them is Here (http://www.fordscorpio.co.uk/cgi-bin/yabb/YaBB.pl?board=admin;action=display;num=1268993371).
If you look at Matt's picture you'll see that the fulcrum,which has the handbrake cable attached, is held in place by a bolt. The first thing to do is partially release this bolt so that you can raise and lower the fitting and work it back and forth having soaked it in WD40. The bolt will come out but then you have to refit the spring and there is no point as the shaft WILL NOT come out as it is held by a small peg inside the body. This peg is clearly shown in the third photo. I personally would say that if this method does not work you are best off getting exchange units.The usual cause is lack of use of the handbrake by leaving the car in Park. I have used this method a couple of times and been ok. It takes a bit of effort and you may have to lever up the fulcrum and tap it back down a few times as well as working it to and fro. Let us know how you get on. ;)

Title: Re: Brake and airbag problems on cosworth
Post by Mike H on Aug 12^th, 2012, 1:59pm

on 08/11/12 at 22:15:21, catalina wrote:

1. Handbrake has excess movement. I read that this is usually the result of corrosion on the adjuster system located in the centre of the brake piston.

Yes usually means a handbrake adjuster on one of the calipers has seized up. It's a bad design!

Quote:

How can I check this and repair if necessary? Is it necessary to remove the complete caliper unit? If so, is it a careful diy job to dismantle and repair/replace the adjuster system?

Only going by what I've read here but seems like wheel off, get some lubricant / anti-seize spray type stuff somehow into the pivot (it has a dust cap or seal so is awkward) then big adjustable spanner onto the lever and try to lever it backwards and forwards. Taking it apart though is a can of worms

Title: Re: Brake and airbag problems on cosworth
Post by Nunnspoet on Aug 13^th, 2012, 8:26am

:) Hi Catalina.

I had excess movement on my Hand-brake lever. On checking the adjuster nuts on the Cable I found that the cable had slipped through causing the H/brake lever to have aprox 2inches play before it started to operate the brakes, ???.

The adjuster and adjuster locking nuts are white plastic. If you follow the procedure for adjusting the Cable you need to make sure that the adjuster locking nut is tight onto the adjuster nut otherwise it will slip again. >:(. On the mating face of the adjuster nut there are female recesses into which the locking adjuster nut male protusions must lock tightly. A real thumb buster, but make sure that the two are tight.

Good luck

Mike 8)

Title: Re: Brake and airbag problems on cosworth
Post by Simmo on Aug 13^th, 2012, 9:05am

The details re the handbrake are Here (http://www.fordscorpio.co.uk/adjhandbrake.htm) however note that 'adjustment' is NOT a substitute for properly working calipers. In Mike's case there clearly was a problem with the adjuster. The access to this, which you will need if you do replace the calipers, is under the heatshields below the floor pan. Ideally done on a ramp or practice as a limbo dancer before hand! ;D

Title: Re: Brake and airbag problems on cosworth
Post by Nunnspoet on Aug 13^th, 2012, 9:35am

Thanks Simmo for the extra input.
I was rushing a bit as one of my, wifes, Scorpio had to be in for it's MOT by 0900. It is going to fail. I discovered a load of rust on the o/s chasis where it descends from the wheel arch towards the sill. :'(. I recon she is probably scrap and was not going to bother, however Carol said check with my local garage man, who I trust, and he said put hen in for a MOT, see what comes up and go from there.

I ain't optomistic :(

Mike

Title: Re: Brake and airbag problems on cosworth
Post by catalina on Aug 15^th, 2012, 11:33am

Just a quick "thank you" for all your advice. I'll am waiting for a spell of good weather and will get stuck in to solving these problems.
After 10 years of Scorpio Cosworth ownership I still marvel at the design of this car. Driving it is pure pleasure;all the controls perfectly located, superb comfort, great performance. I think every budding "modern" car designer should be required to drive one of these before they are let loose on the world. I feel better for that!!!!!! ::)

Title: Re: Brake and airbag problems on cosworth
Post by Mike H on Aug 15^th, 2012, 3:24pm

Warning ~ while it's possible to leave autos in park and not use the handbrake (cos you can, you've got park), always use the handbrake anyway when parking, as not doing so is a sure way to let an h/brake lever on a caliper get seized up. Plus, the pistons won't be adjusted up like they're supposed to.

Guess how I know ;D