Releasing handbrake cable

[ScottR400D]

I want to remove the BMW diff mounting bracket from my R400. The handbrake cable passes through a bracket welded to the diff bracket. It won't come out sideways. It won't feed through back to front, the adjusting mechanism prevents that

Does the bracket have to feed forward off the cable? I built the thing but can't remember how it went on!

[PeterM]

If you did the same as me you probably opened up the jaws of the bracket and closed them after putting the cable in.

[ScottR400D]

That occurred to me but I just can’t remember! 

[Tony Leigh]

Peter,

Are you sure it won't come out back to front. When I built mine I'm pretty sure I managed to squeeze the cable in from the top of the tunnel but it was pretty tight and awkward and I may just have been lucky. I did have the tunnel cover off and I guess you have slackened the cable right off before trying.

[ScottR400D]

Hi Tony. Pretty sure it won't come out back to front. The plastic adjuster is back of the bracket, and it won't go through that of course, nor will it come off the other end, where the calliper is.

My best guess is that I need to unclip at the nearside caliper, take the locating bits out of the two brackets at the back of the tunnel then feed around to the offside until the inner will release from the bracket on the diff carrier. 

Do you remember Bob from the club? Has the CSR260 and built the 320bhp CSRish race car? He's dropping in tomorrow am to have a look at the diff (it's out again). He's on his way to Luke's and I'm hoping they can shed some light on things.

Everyone agrees the noise is unacceptable but still not getting any real suggestions as to what it is. Out of the car the diff feels very smooth and the old tapping seems to have gone. Prop's out too and looks fine.

See you soon hopefully!

[Tony Leigh]

Hopefully Bob will shed some light on diff noise problem, and how to release handbrake cable if you haven't freed it yet. If you do think I can help, happy to pop over, but my car (and experience with Caterham's) is still pretty new.

[ScottR400D]

Thanks Tony. At the moment I’m just investigating everything. Once I’ve got the carrier out and examined I’ll work out something re rebuild. 

Thanks for the offer anyway. I’ve had a lot of support from many, especially on here and from local club members. 

Sadly, the people who should be best placed to help have been conspicuous by their absence..... 

[Geoff Brown]

You can tweak the hole the adjuster is in to remove from the bracket - but like all things when will it fail? Probably when putting the diff back!

It will be a pain but wind off the hand brake cable until the hand brake lever is vertical, remove tunnel cover, disconnect the cable from the calipers then disconnect & remove pulley so the whole cable can be dragged out with the LSD.

Quoting Haynes - 'refitting is the reverse of removal' but don't do what I did & forget to locate the cable adjuster before raising the LSD into place. Much swearing & cursing 

[ScottR400D]

Thanks Geoff, I’d just about figured that out but good to have it confirmed.