Today I fitted the N/S (passenger) polybushed suspension arms, torqued them up and applied threadlock. This time I left the droplink off as I'm yet to polybush the new droplinks as I need to borrow a blow torch to burn the molded rubber eyelet bush out as I don't have anything small enough to support the droplink on my hydraulic press.
I then took the caliper, carrier and disc off.
Sanded the rust off the hub to disc mating face and applied some grease before fitting the disc on.
The carrier was in bad condition, so out came the angle grinder with the flapper disc and my sanding attachment for my electric drill and I soon had it in good order.
One of the sliders was seized solid! The boot had split allowing dirt and moisture in, a tiny bit of rust was enough to stop it moving. So I managed to free it off, remove all of the rust from it and inside the slider hole, grease it up and pinch the slider boot off of one of my spare carriers.
As per usual I was so engrossed in the job I forgot to take photos of how bad the carrier was and the after shot once it was cleaned up. The caliper was also pretty bad so a bit of a wire brush and hammered off the worst of the puffed up rust before fitting new pads with grease on all contact surfaces.
Once it was all back together I torqued the bolts up and sprayed the carrier and caliper with some chain grease to prevent it from rusting again quickly, it shouldn't be too bad now it is going to be a car in a city rather than by the coast.
I then bled the clucth and got my wife to press the pedal to make sure the slave cylinder works and it does.
Then I started bleeding the brakes, I started with the front left as I had the wheel off anyway, as it is non ABS there are two bleed nipples on the front calipers. They were both pretty rusty but I managed to clean the worst of the rust off them, one I could undo with an 8mm socket but the other one was already rounded off and rusty so I had to use mole grips on it. The rear N/S bleed nipple was also rusty and rounded off but again mole grips did the job, however the rear O/S was very rusty and when I went to undo it even with very little pressure the nipple snapped.
So after talking it over with the customer I'm going to fit a new pair of rear flexis, a good used bleed nipple from my parts horde and a good used caliper to the rear O/S.
So once the flexis arrive we should be back in business.
This is the fluid that came out of it, bearing in mind that it has been diluted with fresh fluid as I let it flow for a bit to make sure no debris is in the lines etc.