Page 27 - Karmann Komment - V38 Issue 3

Karmann Komment Volume 38 | Issue 3
KEVIN HOPCROFT BLOG continued...
5678
So, after removing the rear brakes, Unbolting the trailing arms and swinging them downwards,
I removed the torsion bar end caps. My next problem was how to release the tension on the spring plate and after turning the torsion bar one click, how to pull the spring plate back up again onto its rest. See pic 5.
Now normally, with the weight of the car on
the chassis, it is just a case of using a jack to push the spring plate back up again. But with no weight on the chassis, all a jack does is lift the whole chassis. So I had to devise a simple spring compressor as shown on this picture.
This worked great, but I should have investigated the reassembly instructions further, because
I should have refitted the end caps before retensioning to torsion bar. See pic 6.
The result was that, with the spring plate under tension and back on its rest, the end cap would not line up with its fixing holes. I then made another bad decision. I decided to make another tool to force the end caps back on.
KEVIN HOPCROFT BLOG
This turned out to be a very bad decision, because inside the end cap is a large rubber mounting doughnut. The four threaded rods forced the cap on OK but crushed the rubber doughnut and damaged it beyond use.
SoIhavehadtostripitagainandIamnow awaiting the arrival of two new doughnuts. After reading further I discovered that what I should have done is refit the end cap before retensioning the torsion bar. But you live and learn.
Anyway I left the end caps where they were for the time being and proceeded with the reassembly of the rear brakes. See pic 7.
The first job was to clean up the back plates and rustproof and paint them. Next the shoes and springs were cleaned along with the brake adjusters. The back plate was then clamped into place with the axle end caps fitted with new
oil seals and then the new wheel cylinders and cleaned brake shoes could all be fitted.
The good news was that the brake linings were in excellent condition and the drums only needed cleaning and painting. See pic 8.
You can contact Kevin on:
hopcroftscoot@gmail.com
27