924Board.org

ourkid · Posted: Tue Aug 12, 2008 9:28 pm Post subject: Sticky handbrake?

My handbrake only works if i pull the lever all the way up,then wrench it a bit more!
It doesn't make a "ratcheting" noise when engaging either,
I remember seeing somewhere that sticking cables are a common problem,is this likely to be the cause or are there any other linkages etc underneath that can seize?,are the cables supposed to be auto adjusting?

I've only just bought the car (my first 924 so it's all new to me)

Thanks,
Ade.

ideola · Joined: 01 Oct 2004 Posts: 15550 Location: Spring Lake MI

There is an adjustment right at the handbrake that you might want to look into. Be aware that that mechanism is very likely to be corroded, so a dose of some type of penetrating oil (like PB Blaster) might be required before you attempt to break the nuts loose.

The adjuster has a small 10mm nut that locks the adjusting nut into place. Loosen the smaller 10mm nut by turning it so that it moves toward the rear of the car. Then, using a 14mm wrench turn the adjuster in the same direction. This will have the effect of shortening the cable, which should cause the handbrake to engage sooner. BTW, the adjuster itself is sort of like a cylinder with a nut on both sides, which passes thru the funky rectangular piece of metal to which the handbrake lever is attached.

As for the ratcheting noise, it could be that the ratchet mechanism is not engaging correctly, which might also explain some of your issues. The 924 handbrake lever is not exactly the most robust piece of equipment on the car, so you might need to source a replacement. If you do, you can consider getting a used lever from a 944, which I've heard is more sturdy (although I have yet to perform this "upgrade" on any of my cars).
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erstwhile owner of just about every 924 variant ever made

Rich H · Posted: Tue Aug 12, 2008 10:08 pm Post subject:

Better than that check the drums are adjusted, they are fiddly to do but will make a lot of difference to your braking overall.

There are 4 holes in the drum backing plates, the centre 2 have the adjusters in them, they are star wheels with a slotted bolt running through them, if you use a screwdriver and lever the wheels one way they will move the shoes out towards the drums to take up the wear.

Its fiddly to do but will reduce pedal travel as well as improve the handbrake. Just wind them out until they hit the drums then wind them in a little bit more. (Make sure the handbrake it off!) Mind you they might well be siezed...

The adjustments are as follows.

Right hand side:
Front hole: wheel down = shoes out
Rear hole: wheel up = shoes out

Left hand side:
Front Hole: wheel up = shoes out
Rear hole: wheel down = shoes out

You will be under the car trying to work that out for a while!

I'm just up the road in Preston so if you have any Q's feel free to pop round and I'll take a look.

Rich
_________________
1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec

wombat · Posted: Wed Aug 13, 2008 12:17 am Post subject:

hello Rich,
Always so much to tell us all thanks for all your help.

my post however relates to this adjustment issue, I adjusted my drums a few weeks ago after doing front rotors, pads and bearings, I had a few problems with working out the way the adjustment cogs went but got there in the end, However when adjusted they behaved a little wierd, I first adjusted them with the hand brake up three clicks and set them so they were just draging then I checked and re adjusted with the handbrake up 5 clicks and fully down, however when they were adjusted so that at 5 clicks the hand brake held the car there was still slight draging on the drum for half a full turn of the wheels the other half of the turn had no draging whatsoever, if I loosened them off any more so this went away the handbrake would not hold the car at 5 clicks. What could this be and is it fixable without replacing too much. It was a little more draging than was ideal but it would be OK if difficult to fix.
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1977 924 2.0 Auto

Rich H · Posted: Wed Aug 13, 2008 12:28 am Post subject:

Yes, they do do that...

what that is is that you have a tolerance problem, the axle stub is turned to a tolerance of concentricity and the drum to another, put them together and they don't quite line up concentricly (Not sure that is a word, but YKWIM). Just adjust them as best you can, a little bit of drag will not be a problem.

If you wanted you could rotate the drum relative to the stub until the tolerances cancelled themselves out, but its alot of work as you would need to torque up the hub nuts each time. Also there is no promise that they will cancel out...

I suppose you could dial gauge them both... PITA though...
_________________
1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec

Smoothie · Posted: Wed Aug 13, 2008 2:26 am Post subject:

On the lack of ratcheting - The 924 e-brake handle is comparatively flimsy. They're prone to bending, and once they do, the pawl gets out of alignment with the stationary gear, then both the pawl and gear wear to one side and eventually miss each other completely and you loose the ratchet action. (The "pawl" is a little spring-loaded pivoting piece with one tooth that engages the gear.)
Once bent, bending it back is generally futile because it's been weakened even more. -So re-bending is a very temporary fix. The later 944 e-brake handle is much more robust and swaps right in (same hook on the end to accept the cable end, and same bolt pattern to attach to the car). They're usually available on eBay.
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"..it's made in Germany. You know the Germans always make good stuff."

'82 924T, US version, dark green metallic, 5 speed Audi 016G gearbox

wombat · Posted: Wed Aug 13, 2008 6:20 pm Post subject:

Rich H · Posted: Wed Aug 13, 2008 6:28 pm Post subject:

Next time you are in Preston I'll let you buy me a beer.
Proper warm bitter though, not that fizzy stuff....

I hopefully will have a new pair of drums by the weekend, so I'll have a play see how hard it is to dial out the tolerances.

_________________
1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec

flyguy · Joined: 31 Oct 2008 Posts: 75 Location: Hamilton, Ont

!tom · Posted: Tue Feb 24, 2009 5:57 pm Post subject:

RobertN · Joined: 19 Apr 2015 Posts: 142 Location: Lisburn Co Antrim

Hey Rich. Just read your post on the adjuster cogs adjustment. Many thanks, as I was confused as to what direction up or down on each cog on the back of drums! Makes sense now as I have been looking at the Haynes manual and was trying to figure out why they didn't mention which way to lever front and rear cogs and I didn't want to be adjusting the wrong way for ever!! Lol Will do this Saturday as MOT due Monday!
Cheers again, life saver!
Robert.

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Robert.
Porsche 924 N/A 1984.
Electrical Engineering Sales to Control panel builders.

RobertN · Joined: 19 Apr 2015 Posts: 142 Location: Lisburn Co Antrim

Adjusted brake shoes as per Rich advice on cog adjusting direction!! Nice one. Cheers mate worked first time thankfully no need for wd40!! Handbrake holds firmly on 3rd click.
_________________
Robert.
Porsche 924 N/A 1984.
Electrical Engineering Sales to Control panel builders.