Handbrake on Cortina base

[fredsajs]

Can anyone advise on floor handbrake ratchet travel ?.
I have failed MOT due to excessive travel of 9+ notches on handbrake.
It only pulled up 3/4 befor test !.
Tester states cable requires replacement due to nylon curling adjuster on metal cable worn during test on road roller.
Any recomendations.

[Dane_Rescueman]

Re: Handbrake on Cortina base

Fred, Berlis in the past did have trouble with the handbrake. The problem is often caused by the original double lever system. (I have just fitted a new cable for MoT reasons too.)
A good modification is to weld a strip of steel along the underside of the push rod from the handbrake to the operating bellcrank. The angle and gearing of the bellcrank is not ideal so it needs all the help it can get. This longish pushrod is steel strip but flexes under load; in effect, putting a springiness in the linkage. The welded strip along this strip, making it "T" section, prevents any bending or springiness making the movement more positive. This mod was detailed in a Pitstop many years ago.
Ther position of the small cable brackets where the cable enters the outer sleeve on the LHS and the adjuster sleeve on the RHS is critical. If adjustment is difficult as my old cable was, move these brackets rearward if you can.

Of note my old cable was original Cortina and had a steel ferrule and various locknuts to make adjustments. The new one is like yours. Adjustment is carried out by winding two nylon nuts along the spiral cable outer. To me this is a bit gash and I can see that after a while the nylon will harden and give up the ghost. Progress eh? At least there is a whole lot more adjustment available than with my older system.
I can now lock up my rear wheels when slowing using the handbrake but I cannot get the adjustment down to the recommended MoT of three clicks on the handbrake lever. About four to five is what I obtain.
Good luck with it.

[fredsajs]

Re: Handbrake on Cortina base

Have found handbrake fault .The nylon adjuster had resited itself back down into outercase, Seperation and re`adjusment with conformation of nylon pip engaged worked well for MOT bloke was more careful on application test. Would you believe he also said he could live with exsesive pedal travel.So passed for now, but did give a reminder on areo cap inner cap seal perishing over intake hole, but he liked my modication tank breather one-way aluminium inline valve mounted to side of escort tank.
Thanks for all info Dane,