The saga is almost over - 2005, C220 CDI Classic SE, S203.208 (Estate), OM646.963 Engine

[Oldspanners]

If I read these two drawings correctly... (using the 300 mm diameter discs) the disc would end up sitting 3mm closer to the inner side of the caliper carrier.... but its sitting against the outer edge... so can't be this idea?

Unfortunately it doesn't give the thickness of the flange which would change where it sits on the hub but if the material is the same thickness then you're correct.

 

[RhodieBill]

The two drawings above indicate the other way around.
Measuring from the rear face of the disc, the height (offset) is the same in both cases, but the 300mm disc is 3mm thicker towards the outer face.

Secretly, I think the OP is rebuilding the entire car and is using this forum as a knowledge base to save buying a Haynes manual. This thread will run for years until the last bolt has been discussed, then he will publish the redacted results and start another thread on his next car!

If we all live that long...!!!

 

[Jim2]

The two drawings above indicate the other way around.
Measuring from the rear face of the disc, the height (offset) is the same in both cases, but the 300mm disc is 3mm thicker towards the outer face.

Secretly, I think the OP is rebuilding the entire car and is using this forum as a knowledge base to save buying a Haynes manual. This thread will run for years until the last bolt has been discussed, then he will publish the redacted results and start another thread on his next car!

Maybe so, but I'm sure that people are learning from it too. I am anyway, and at this stage, it's like watching a series on NetFlix,,,,,and you can't wait to see the end, and how it will turn out !!!

 

[davidsl500]

I have had teeth pulled without anaesthetic less painfully than the current thread! I'm having flashbacks to Callum...

 

[d215yq]

Checked this and yes the disc bolt hole does line up. Just have an old sheared off bolt stuck in the hole where that counter sunk bolt should go.



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Could it be that the remnants of this bolt are preventing the disc from mating properly to the hub?

 

[Jim2]

Could it be that the remnants of this bolt are preventing the disc from mating properly to the hub?

If it was protruding a bit, and not lined up with it's corresponding hole, it could indeed be throwing of the the disc alignment.

 

[RhodieBill]

Could it be that the remnants of this bolt are preventing the disc from mating properly to the hub?

Not if it is lined up with the nole in the Disc.

 

[Taffy7hfa]

Hi NBurns, Just spent a happy hour reading this fascinating thread , Any chance of some photos of the car in its entirety ?

 

[NBurns]

The two drawings above indicate the other way around.
Measuring from the rear face of the disc, the height (offset) is the same in both cases, but the 300mm disc is 3mm thicker towards the outer face.

Secretly, I think the OP is rebuilding the entire car and is using this forum as a knowledge base to save buying a Haynes manual. This thread will run for years until the last bolt has been discussed, then he will publish the redacted results and start another thread on his next car!

Umblecumbuz, you know me too well already!!!! How did you figure out my overall plan?!!!!



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[NBurns]

Maybe so, but I'm sure that people are learning from it too. I am anyway, and at this stage, it's like watching a series on NetFlix,,,,,and you can't wait to see the end, and how it will turn out !!!

Credits will be given at the final episode!!!!!


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[NBurns]

Could it be that the remnants of this bolt are preventing the disc from mating properly to the hub?

Yes, you are correct. Only by about 3mm before as I have been attempting to get the damn thing out using every single method I can think of. It is now about 2mm but I can measure that.



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[NBurns]

If it was protruding a bit, and not lined up with it's corresponding hole, it could indeed be throwing of the the disc alignment.

Yes, yes. You're absolutely right. Even if that was just 3mm, that would clearly put a slight offset onto the wheel which would in turn cause an offset between the pads.
My plan of action. First, get that sheared bolt out. Secondly, check the NSF wheel just in case the same has happened. Second, now that I have removed the pins, clean and re-grease them thoroughly. Thirdly, if it is possible, remove the brake calliper piston, clean thoroughly, re-grease and replace. Repeat on NSF if required for everything. Then replace all brake fixtures, re-fill reservoir with new brake fluid (as I've lost some already), bleed the system of air and then onto the suspension arm on the OSF. Damn!!! Forgot about that. Already found a reasonable priced one online, just need to get it and fit it.
What is a failure on the lower rear wishbone arm anyway? He showed me where it was but not what the failure was.

 

[NBurns]

Not if it is lined up with the nole in the Disc.

But if it isn't and wasn't.......


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[d215yq]

Yes, you are correct. Only by about 3mm before as I have been attempting to get the damn thing out using every single method I can think of. It is now about 2mm but I can measure that.



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I'm not sure I fully understand...

Is the sheared bolt stopping the dsic coming off, as in it's sheared with the disc already attached? And if so how is it also stopping the disc from mating with the surface? It was my understanding that the sheared bolt was not holding the disc on so was not really a problem as that bolt isn't needed anyway? But then I thought it was the caliper bracket that was stopping the disc being removed and my understanding is that has since been removed so the dsic should now come away...?

Besides if it is really 3mm then that could be your problem. It may not be enough to centre it but it maybe enough to make it stop catching?

 

[NBurns]

Hi NBurns, Just spent a happy hour reading this fascinating thread , Any chance of some photos of the car in its entirety ?

Is that to prove there really is a car?!!


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[joderest]

Had this on a Mini, screw sheared off in the hub.
Drilled it out with a drill just under the screw size and then picked out what was left, then run the correct tap through to clean up thread.
You can get away with out them, but the point that the remains of the screw could be holding the disc off the hub is a valid one, as the disc will fit in five different positions with out using the screws, If you cannot get them out, either file or grind them flat. The wheel bolts will hold the disc on, but be careful not to get anything behind it when fitting.
Its always best to use the retaining screw though.
One day we will have a resolve to this issue.

 

[Blobcat]

One day we will have a resolve to this issue.

Resolved

 

[umblecumbuz]

So - what is the diameter of the disc, now you have removed it?

 

[NBurns]

I'm not sure I fully understand...

Is the sheared bolt stopping the dsic coming off, as in it's sheared with the disc already attached? And if so how is it also stopping the disc from mating with the surface? It was my understanding that the sheared bolt was not holding the disc on so was not really a problem as that bolt isn't needed anyway? But then I thought it was the caliper bracket that was stopping the disc being removed and my understanding is that has since been removed so the dsic should now come away...?

Besides if it is really 3mm then that could be your problem. It may not be enough to centre it but it maybe enough to make it stop catching?

Sorry. I have now been able to remove the disc. And in doing so found the sheared off bolt.


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[NBurns]

Apologies for the very rough measurements. If my vernier calliper set suddenly turned up I could measure this more accurately.


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