| TD6 '02 Repair to Front Brake Splash Guards | |
My MOT guy doesn't like my rattling front brakes, seems every year one side or the other has a rattle, so set out to effect a repair in preparation. This required removing the splash guard, so I set about dismantling the front brakes. For the photos I have used the left side (passenger side RHD). I was also able to resolve a seized on disc retaining plug (see here).
Tools:
Trolley jack
Axle stands
Wheel brace
4mm allen key (or cold chisel if needed)
Torx 25 for guide bolts
16mm socket for carrier bolts
10mm socket or spanner for splash guard bolts
Hacksaw
Hide Hammer
Ratchet and breaker bar
1. Dismantle front brakes
I won't go into detail on this one, suffice to say, jack up car, support with axle stands, remove road wheel, remove caliper and carrier, undo retaining plug, remove disc (bash both sides with hide hammer if stuck)
2. Remove splash guard
a. Undo the three small bolts with 10mm spanner/socket and remove with washers.
b. Rotate splash guard to a suitable point and hacksaw through at the thinnest point
c. Remove splash guard by bending back at the cut point to get enough clearance to remove from hub
(yes, not removing hub to do this!)
d. See enlarged holes where splash guard (aluminium?) has corroded away
3. Clean up and effect repair
a. Clean up hub and fixing holes for splash guard with wire brush then kurust it
Fixing holes kurusted to help prevent future corrosion
b. Bend "bent back bits" on splash guard back and forth until they break off and sand with green coarse paper. This then allows easy fitting and removal of splash guard in the future, with minimal impact on the "protection" it provides....
See 1 cutpoint, and 2 bent back bits to be removed
After removal at 3
c. Clean off splash guard and protect exposed metal with suitable paint/product
d. Source suitable washers for both sides of the splash guard
Apart from bottom right all washers are "rustproof"
 | | Click image to enlarge |
e. Refit splash guard with new washers and tighten, ensuring no rattling remains
f. Note: plenty of clearance on the inner side for the washers and bolts
Job done!
3. Refit Disc and Caliper assembly
Note: you may need to bend back the splash guard near the upper guide carrier fixing to get the bolt back in.
Comments:
Elswhere on forum other have advised the cut method to remove and fit new splash guards. Must take some serious bending to get the new one back over the hub? Preferred my wider gap solution. .
Experience is the only genuine knowledge, but as time passes, I have forgotten more than I can remember 
Volvo V70 P2 2006 2.4 Petrol 170bhp Estate SE
MG Midget Mk1 1962
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5th May 2013 8:31pm
..wikified.
