Hello guys,


Been looking on the forum for a while on past posts as the handbrake on Mondeos seems a regular thing! This is my 3rd Mondeo and 2nd where I've had to change the calipers. The 1st was a MK2 and had no problems after that however my current 2005 MK3 could make me cry!!


Changed calipers, discs and pads in August as one had seize and I've had nothing but problems since with the handbrake all but not working! Took it back twice to be adjusted and within days as bad as it was. The garage contacted Ford who said it could be cables or the ratchet but they didn't return my call on a price so I went elsewhere to get the cables done.


Came back fine but within a few days the handbrake is back to its highest before it'll hold and even then it has me worried. Took it back to the 2nd garage who stripped it down and showed me that one of the calipers was faulty. So back to 1st garage who changed both calipers no quibble. Collected car last Tuesday and again within a couple of days its basically as bad. I'm at my wits end with this and I've called Ford myself who say it can't be the handbrake as a ratchet fault would mean it wouldn't physically stay up so must be either a part or set up fault. If I press firm on the brake and pull the handbrake up and down a few times before stopping it does seem to hold better.


Sorry for the rant but anybody else had the same and could possible direct any help? This has been going on for nearly 5 months and even with a new set up only just pasted its MOT with 16% efficiency!

 

Has it got the self adjusting lever mechanism, iirc they recalled them as they were shite, yours might have slipped through the net.

Other than that if the cables are new and the calipers are to, its a pretty straight forward system. Are the discs and pads in good condition? Are the handbrake levers back at the stops when the handbrake is released? Were the calipers pumped out via the foot pedal before the handbrake cables were attached?

 

An 05 has a manual adjusting mechanism underneath the car.

I would try adjusting it. It is a pain though without a ramp. In an ideal world you would do the job on a ramp. This is because ideally the exhaust and heatshield require removing; not handy if both have corroded fixings. There is a way around it:

-Drop the exhaust from the hangers and support the weight (the flexi pipe up front cannot be bent much at all before it breaks). I would recommend to keep the exhaust as close to the car as possible.
-Drop the heatshield onto the exhaust
-Grab a deep fit 17mm socket and put it onto a 1/2" wobble bar or extension bar with a flexi joint (2 extension bars may be required).
-Adjust until you get 4-5 clicks at the handbrake.

Furthermore, it is worth mentioning a few more things. If the handbrake balance bar (where the adjust is) is not sitting level, the handbrake mechanism will never work right. It could be down to the wrong cables being used or a seized caliper.

 

This is good advice for adjusting the cable, when I do these I like to slacken the cable off first and then move onto the calipers . Make sure the pistons in the calipers are fully wound back ( one maybe a left handed thread ) . Now the important bit is apply the service brake first ! Then when you have a foot brake you go back under the car and adjust the cable as Chas has mentioned . One last thing, ulturnatly adjust the cable and then check the wheels spin freely. Your looking for 4-5 clicks on the park brake.

Hope this helps

Adder