Fixing a Frozen Handbrake in a MkI

From: uunet!hou.Sperry-Sun.COM!bshaw
Date: Wed, 31 Jan 1996 13:04:32 -0600
Subject: mki mr2 handbrake

     This was the requested hand brake fix for mk ones w/ frozen cables...
     
     Here's what you will need:
     materials -
     2 ~15 foot sections of 1/4 inch cable (preferably plastic coated) 4 
     sets of cable clamps (to make loops in the cables)
     tools -
     something to cut the cable (cutters)
     something to crimp the clamps (pliers with _alot_ of leverage or a 
     hammer)
     
     procedure:
     This will take at least four hours, nice to have another car around to 
     get stuff too!
     Lift car and remove the middle and back plastic mud guards on the 
     underside. 
     Remove both parking brake cables. 
     This will take awhile and require a good bit of disassembly, just 
     remember what you've
     done and keep all the peices organized. Try and understand how the 
     whole mechanism works
     while you are doing this.
     Near where the brake lever comes down, there is a bracket to which 
     cables were attached.
     Remove that bracket from the car and bring it to a work area.
     Attach the new cables to the bracket by making loops using the clamps. 
     These loops will 
     be permenat so make them small and very strong.
     Mount the bracket with the new cables back on the car.
     There is a bolt which adjust the tension in the cables near where the 
     brake lever comes
     down. Adjust it to a middle-loose position for later. Remember you can 
     adjust this later,
     but once the loops are crimped on both ends of the cable - there is no 
     adjusting them.
     Run the loose ends of each cable through the guide eyes on the bottom 
     of the body.
     I removed some unnessary hardware near each of the rear brakes. It is 
     a plate which held
     the old cable.
     There is a lever with a hole at the end which pulls the disc pads down 
     on
     the rotor. The loose ends of the new cables are going to loop through 
     that hole on each
     side of the car. Make a loop like the ones on the front and pull the 
     cable very taut. Make
     sure this loop won't slip under the tension of the brake. Now you can 
     test the system.
     The wheels should roll freely when the lever is down, and be firmly 
     stopped when the lever
     pulls ~6 clicks. If this is not the case, use the bolt (under the 
     brake lever) I refered
     to earlier to adjust the tension.
     I had to cut my plastic mud covers to get a good fit during 
     reassembly, do it as needed.
     
     Good luck, email if questions arise. Bobby
     85na
     rshaw@bit.csc.lsu.edu