Handbrake worry

Q I have a 2002 Vauxhall Vectra C 1.8 for which the handbrake was not working. I checked the rear calipers and the offside rear caliper handbrake cam/lever was not working correctly; the nearside rear caliper seems to be fine. I fitted a new caliper and the handbrake is now holding the car, but the handbrake lever comes right up and has no reserve travel left. The handbrake lever has always had a long travel but never this amount. The handbrake cables feel free on both sides and the caliper levers are both being pulled on when the handbrake is applied, although the new caliper lever moves about 10mm and the rear nearside moves about 20mm. They both return to their stops when the handbrake is released.

As you know, the handbrake on this model is self-adjusting via a mechanism on the lever and I have even pushed the spring/piston back on the lever and locked it in the so-called travel position to see if that would reset it, but it made no difference. Is there any way of checking to see if the self-adjusting mechanism is working? My thoughts are that the handbrake lever is not self-adjusting, but the only way I can think to prove it is to replace it and hope for the best. Craig Christie

Before we could reply, the reader sent a second email...

I have sorted the handbrake problem. I removed both rear calipers and wound out the pistons until I could just fit the calipers over the pads. The handbrake lever travel is now only 4-5 notches and the handbrake holds perfectly. The only downside I can see is that the handbrake levers on the calipers now have only a limited amount of travel before the handbrake is fully applied (they both return to their stops when the handbrake is released). I just hope they have enough travel to keep the mechanisms free and working.

Craig Christie

A Provided the handbrake lever is returning to the stops and the brakes are fully released when the handbrake is off, this should not be a problem. One important point to remember when fitting a new rear caliper is that the handbrake cable should not be connected until the caliper is fitted, bled out and the brake pedal has been pumped to ensure the pads are fully in position. This allows the self-adjusting mechanism in the caliper to operate correctly, ensuring optimum operation of the handbrake.

It might be tempting to fit the cable while the caliper is disconnected, as the lever can be swung round to save deadjusting the handbrake, but this will be detrimental to the operation of the self-adjusting mechanism. According to the information I have, your handbrake mechanism is automatically adjusted at the lever. This can be reset at the lever by pushing the rod under the rear console, back against the spring.