Handbrake fix and adjustment for Ducato/Jumper/Boxer/Relay/ProMaster X250.

How I replaced and adjusted the rear handbrake/parking brake drum brake shoes inside rear disc on my Fiat Ducato X250 from 2010, and how I made a perfect tight adjustment to gain back the braking power necessary for parking on slopes.
I used the following torque settings:
Brake disc to wheel hub = hand-tight (max 12 Nm)
Brake caliper yoke to car = 210 Nm (Bolt size M16)
Brake caliper to guide pins = 30 Nm (Bolt size M8)
Pull-rod adjustment screw = 15 Nm (when pulled to the 6th click)
Wheel bolts 15" = 160 Nm (Bolt size M14)
Connect with me on Instagram: / valsted.makes
▬▬▬ Contents of this video ▬▬▬
0:00 - Intro
0:14 - Showing long lever travel and faulty brakes.
0:32 - Tool for the job.
0:44 - Raise and support vehicle.
1:10 - Releasing tension of the parking brake cables.
1:50 - Removing brake caliper, pads, and yoke.
3:35 - Removing brake disc and internal drum brake shoes.
4:01 - Releasing drum brake shoes turning tooth wheel.
5:35 - Removing hand brake shoe adjuster mechanism.
6:13 - Cleaning ABS sensor ring.
6:38 - Preparing new parts.
7:30 - Cleaning tooth wheel and mechanism.
8:15 - Installing the brake mechanism.
8:29 - Installing new brake shoes.
11:10 - Installing disc and adjust the shoe position.
12:24 - Installing brake caliper yoke.
14:26 - Installing brake pads and caliper
16:32 - Adjusting the left side.
17:02 - Checking front pull-rod mechanism.
17:24 - Adjusting hand brake lever travel and brake power.
18:27 - Tightening wheel bolts.
18:57 - Lower car and test drive.
#fiat #ducato #campervan #jumper #Boxer #Relay #ProMaster #X250 #vanlife #mechanics #brakes #rear

[@westwasbest]

This is one of the best videos I have ever seen! As a mechanic myself, this gentleman did a fantastic and thorough job, and the best part of this video is the fact that he didn't bloviate and blabber in the beginning in the middle and during the video! All of you other KZbinrs that make videos, pay attention! Nobody likes to hear 10 minutes about your personal crap or all the nonsense during the video, the best part of this was there was no talking!

[@valstedmakes]

Thank you for your kind words.

[@martinvandyke3316]

This video saved me a fortune ! Took it to one garage 3 times & they still didn't get it right. Had it booked in somewhere else but did it myself after watching your video. Garage I was booked in with said, yhey have mechanics often coming in for them to fo it because they can't ! 😂😂😂😂😂 Thank you brother 👍

[@valstedmakes]

It sounds good. Thank you for your story. Have a great summer.

[@petersovakopernicky9050]

I like when amateurs mechanics got better tools than pros

[@daleleonard9486]

well done! exactly what i needed to see. crystal clear video without all the jibber jabber. :)

[@valstedmakes]

Thank you.

[@GP-pw5wb]

At the beginning he states he is not a certified mechanic, i would to say he has a professional work method and certainly knows what he is doing. Nice to see a bit of H&S with the vehicle supported on axle stands. The last guy i saw doing this job was just working off the trolley jack accident waiting to happen.

[@valstedmakes]

Thanks for your comment. I’m an aircraft mechanic. 😉

[@GreyJedi73]

Outstanding information. All I needed to know as I embark on my own promaster break adventure! 👏 Thank you 😊

[@terrywhite4512]

Great video, and easy to understand with all information needed I will be doing my motorhomes brakes this weekend ready for mot.

[@FOXY-2023]

Great video. Finally someone that clearly know what there doing

[@valstedmakes]

Thank you.

[@craigieboy66]

Great video thanks👍, I took the hub off and cleaned and re-greased the bearings, found it easier to fit the shoes back in that way as well 😄

[@nevergoingtoupload]

Great video. My handbrake has been weak for a while now but all adjusted up and solid on 6 or 7 clicks. Thanks.

[@valstedmakes]

Thanks for your comment. I’m glad the video could help you, it’s good motivation to make more. :-) Have a nice day.

[@colinsvid]

Another man who clearly loves his van , great video thanks

[@valstedmakes]

Thanks 😀

[@IntrovertAbroad]

Thank you so much for the effort you have gone to in making this video, it’s so helpful and clear! Exactly what I needed. Happy travels! 🤙

[@valstedmakes]

Thank you. I’m happy you find it usefull

[@nickalina]

Thank you for this excellent video. I now have a good working handbrake.

[@thezerocool22]

Visually really clear, great vid 👍

[@jozefdt8731]

Ďakujem pekne...prajem pekný deň

[@Aikijim2007]

Cracking video. Very concise and well done.

[@slimbo74]

Great video, simply step by step guide, thx

[@williamrafferty14]

Excellent video - exactly what I needed to see ! Well done!

[@valstedmakes]

Thank you for your feedback!

[@petrjandal5197]

Thanks it helped a lot, specialy with adjusting the brakes.

[@jimgibson4760]

Marvellous demonstration. Many thanks.

[@valstedmakes]

Many thanks.

[@qshufle]

Thank you! Great from France

[@nathanielseeboruth1328]

Great video nice detail and clear no nonsense!!

[@valstedmakes]

Thank you.

[@Telsau]

Thanks a lot ! Excellent job and excellent video ! It helped me a lot !

[@valstedmakes]

Thank you for your reply. Great to hear when someone uses the video. 🙂

[@wjones6606]

Very well made, clear video great.

[@valstedmakes]

Thank you very much.

[@przemysawkisluk5839]

Nice rubyred colour od your van👍

[@michaelwitt8070]

Super gut, vielen Dank fürs zeigen. Grüße aus Deutschland

[@Loki_on_tour]

thank you from germany

[@zeenalabdeenbassim4587]

En av den bästa klipp jag har sett hittills 👍

[@valstedmakes]

Mange tak.

[@daposlovakiask8796]

great video, I'm going to do the same job tomorrow😎

[@valstedmakes]

Thanks. I hope it will work for you.

[@Calzadar]

Great video, thanks!

[@valstedmakes]

Thank you. :-)

[@Awalk05]

Your a life saver 👍

[@grullon120]

thank you so much

[@666chum]

Nice. Thanks

[@joesmith063]

Awesome video helped alot

[@valstedmakes]

Thanks alot. I'm happy it helped you.

[@TheAirConGuy]

Top marks!

[@rosangelollinharesdasilva4724]

Excelente. O criador do vídeo esta de parabéns !!

[@valstedmakes]

Grata pelas suas palavras. Tenha um bom veräo. (Google Translated)

[@LynPoddley]

Hello Valsted.. Greetings from Lake District England... "OH!" how I wished I had watched your Video of your job today... Although Female I do most services on my Peugeot Boxer 2009 L3H2 Motorhome.. and I have had to replace rear Hand Brake Cables... I have done everything you have done.. Only difference is.. it took me All Day and fit them upside down or back to front.. Amazed that they work when handbrake applied... But! will definitely re-do them tomorrow... I put springs on the rear of lining... and not as you have shown on the front.. (hence the 2 hours trying to line up linings)... and I think I fit the hand brake adjuster (toothed wheel) upside down and the Hand Brake Cable adjuster also... practically not possible to do it that way... When removed disc... another 2 hours trying to get them off because of 3mm rust rim behind the linings... So! Tomorrow I will follow your Excellent Video.. and re-fit to your exact way of doing this simple job... Lyn Poddley.. Poddley Tale's Euro..

[@valstedmakes]

Thank you for your comment. I good thing doing this again is that now everything is easy to disassembly. :-) The springs is always hard to maneuver around inside drum brakes, but I hope my video will help you to make it function correctly. Note: Many drum brake system, have a small metal plate contacting the tooth adjuster, to automatically adjust the drum pads to the correct position. I works when engaging the handbrake. (Must be engaged many times after new pads are installed) This system isn't installed on these cars, but a good thing to know on your next car. I wish you an easy install, and a good summer.

[@LynPoddley]

@@valstedmakes Thanks' for reply... They will "Whizz" off now... Lyn...

[@user-tg7hc7et2z]

Спасибо за подробное видео 👍

[@valstedmakes]

Thank you. 🙂

[@stanislawsteczko8998]

Great video, thank yoiu.

[@valstedmakes]

Thanks.

[@nikroche2621]

Thank you..

[@stanekeda]

Thanks!

[@filippakua5322]

Great video, thx

[@valstedmakes]

Thanks. I'm glad you liked it.

[@Awalk05]

Can’t get the rotor on the right side everything is in properly, mirrored left side any ideas?

[@chrsfrm]

Thanks, a great video. Just had a garage do this on my 2008 Ducato motorhome. Due to it's 4250kgs weight it is still not better. A real problem for large motorhomes at MOT/ITV test times.

[@valstedmakes]

Thanks. Waw a heavy build. I agree, this brakesystem will have a very hard time holding that load. Maybe a solution for you could be a Pedal Depressor. "Deluxe" version: www.lislecorp.com/specialty-tools/throttle-pedal-depressor DIY here: kzbin.info/www/bejne/hmG4hYuFmLWeibs

[@GFT-Workshop]

@@valstedmakes Pedal depressor is no good for the vans annual MOT test, the handbrake has to meet 16% efficiency. So you take the brake effort from both sides, measured on a rolling road brake tester, add them together and divide by the vehicles gross weight. We struggle on our 3500kg vans, its going to be even worse on a 4250kg van. These handbrakes are just not very good.

[@valstedmakes]

@@GFT-Workshop Hello and thank you for your comment. I completely agree that these brakes are bad, and the problem will only get worse with higher weight. We don't have exactly the same conditions here in Norway. The car must brake left/right within 30%. I'm not familiar with the minimum brake efficiency, but the brakes should be able to hold the car on a slope. During the last EU inspection, I had trouble getting the car to brake evenly. It turned out to be the mechanical brake unit in the brake drum that had rusted together in the left drum. I cleaned it and also replaced both brake cables. Now it brakes perfectly again, and I can easily lock the brakes on a gravel road, even at speed.

[@francoislegac4985]

Très bonne vidéo,pour mon jumper 3 merci beaucoup.Very good movie for my jumper thank you very much.My english it no good.

[@valstedmakes]

Merci beaucoup. I’m happy your Jumper liked it.

[@marcwaalboer]

The spring clips that took you 2 hours can also be installed in 2 minutes! Clamp a thin self-locking hose clamp around it, compress the clamp spring using a water pump pliers, tighten the self-locking hose and then put it in place with needle nose pliers!

[@totopareil1220]

Hi, excellent video, thank you. Why did you change all this parts? What were the « symptoms »?

[@valstedmakes]

Hi. Thank you. The symptom was no brake power, and total price for spareparts was around 50$. There are many parts but with low cost I recommend replacing them, when you service drum brakes. You can't see from the outside why they work badly, so it's easiest to have them ready.

[@hansdunkweiler1220]

Top

[@huertix4393]

Love the video. Many Thanks. I have planned to replace Disk and Pads, but looking to your video I will replace also hand-brake pads... Just one question please. How much torque (Nm or Lbs) do you apply to these 22mm bolts ??? Many Many Thanks

[@huertix4393]

Fuck,, In the description. Forgive me....

[@valstedmakes]

Thank you. Replacing the hand brake pads will not take a lot longer, and you rear brakes will be as god as new. :-)

[@minigolf17]

thanks perfect! just a detail, the torque wrench, you only need to make 1 click. for wheels not very serious but to make a precision tightening you risk all breakage. because the 2 click goes beyond the expected torque.

[@valstedmakes]

Hi Michel. Thanks for you comment. You must never proceed turning the wrench with force after you hear/feel the click. If done correctly the second or even the fifth click will never go beyond the torque setting if the torque wrench is correctly calibrated. But you can experience some degree of rotation during the second click, if the area between the bolt and the component is dirty, or you tighten off angle, or in other bad conditions. One tip during the cable adjustment. To gain the correct cable tension, you must click more times, to overcome lack of willingness to clean the rusty parts. The rusty parts will result in too high tightening friction, and if you stop after first click, you properly will end with a lose handbrake again.

[@mikelane4896]

Stupid comment ! If the torque wrench is set do a certain tightening torque how come it will go over this if you release the wrench to rest and then proceed forward until it clicks again? Fool !

[@michaeldenman9223]

Good video , wish I’d seen this before I helped change shoes and pads on my friends duke .. nightmare getting carrier bolts out as they had been loctited ! Just out of interest any idea what socket / torx is the shock absorber bolts ? Cannot find any information about them .. thanks for easy to follow video..

[@valstedmakes]

Thank you. I can check tomorrow. I'm editing front spring replacement, horn replacement and gear oil change in these days, so new videos is in the making.

[@valstedmakes]

Hi again. Sorry my late reply. I think the external torx is a E24, the biggest I have is a E20, and it won’t fit. Point to point distance is 21.4 mm on the bolt. In a hurry or a Sunday I will try using a 19 mm Hex socket, it fits snugly.

[@michaeldenman9223]

Thanks for your advice.. I will try measuring and see how it goes...

[@bengtekelund8304]

Inget snack, bara verkstad. Det här var bra.

[@valstedmakes]

Tack så mycket. :-)

[@elisabethguignolet8672]

tres bonne et excellente video . un petit regret manque les couples de serrage .

[@valstedmakes]

Thanks

[@rwmgaming489]

Just what i was looking for, great video! My handbrake is not working at all and i will be doing this at the weekend, what are the torque settings you used please?

[@valstedmakes]

Thanks. I have added the torque settings I used in the description. I wish you good brakes again :-)

[@balda8839]

Super sk

[@maan7358]

I did everything in this video and then replaced the cables, I can still pull away at idle in third gear. Took it all apart and redid it. Same. Do you have to use Fiat Original parts or are Bosch ok.

[@valstedmakes]

Hi. If you can pull away with rotation wheels you have adjusted the brakes wrong. Mine is locked, but they need to be adjusted regularly. I don’t use original parts but as good as

[@user-rb3jk6ow9n]

Я из росии спасибо большое отличное видео

[@valstedmakes]

Super you could use the video. Thanks for the comment.

[@oriolcami4763]

Num referenc for breaks?

[@baloghtams68]

How much torque should the rear wheel bearing bolt be tightened? :)

[@valstedmakes]

To my knowledge there are two types. One with a straight shaft, and one with conical shaft, and for the conical it is especially important not to tighten too hard. I do not have a precise tightening torque, but have read between 200-300 Nm, it is important to rotate the wheel while tightening the nut. The wheel must rotate freely and must not drag. The straight shaft just needs to be tightened. Note if you need to change the bearing on the conical shaft, they are known to fit very well. There are pullers made for it, but a good slide hammer can be used too.

[@larezjesus5504]

what type of vehicle and From what year to what year this type of hand break is this for ..thank you

[@valstedmakes]

See the title. They are from 2007 and up. I think the facelifted non-US versions from 2014 has the same brake system (X290).

[@pippaspaws262]

Can i ask what brand brake pads you used?

[@valstedmakes]

Hi Pippas Paws. I have used NK brakeparts for many years. Always happy with the quality. www.nk-autoparts.com/

[@djameldj5133]

👌👌👌👌👌👌❤

[@aengus.l]

What do you do at 17:17 if it doesn’t sit fully down? Thanks

[@valstedmakes]

Adjust the cable from the handle to the link.

[@gmykolas]

Did exactly the same. There are no enougth strength to pass through technical inspection in Lithuania

[@erdimetalia2407]

I got the same sh.... van I have pun new brake shoe and discs. but handbrake when is going forward 😕 don't hold. in reverse they are solid

[@rafaszewczuk8674]

Have you fixed this? I have the same problem.

[@valstedmakes]

I agree with you, it’s a bad system, but great solid brake power is possible. The mechanical brake pad actuator, the one the cable is attached to must turn smoothly. I need to lubricate them to go through my last check.

[@jkortet9797]

Look's so simply, but these have few things which i have to fight many hours. Why the other companies spare part are much thin than Fiat original brake shoes?! Other companies spare parts always dont have good handbrake stopping power and it will be rejected on the inspection.

[@valstedmakes]

I have not experienced that non-original spare parts do not live up to the manufacturer's specifications. But I always buy "same as original" spare parts if I do not buy from Fiat. I had the car for EU control after this video and they were accepted. Maybe I misunderstand your post, then feel free to write again. :-)

[@rogeryates4205]

Get some pbc. on those bolts.**********

[@valstedmakes]

Hi Roger. Can you explain pbc? Thanks in advance

[@carlwebster1685]

Easier if you take the hub off also where is the rest of the adjuster pawl

[@valstedmakes]

Hi. I don’t think there is a need to bring the bigger tools out to remove the hub also. Actually I think it’s easier to use the side of the hub during the installation of the last spring. But to be fair I haven’t tried it on this car. The brake system does not include the automatic adjuster pawl, I think you refer to. Brake shoe adjustment is performed manually through the bolt hole as shown.

[@gmykolas]

After you do this, if you have light rear side of the car, like tent, there are no enougth strengh in brake mechanism. Stupid construction actualy

[@valstedmakes]

I agree. Bad system, but a solid brake is possible. But you need to adjust regularly

[@rudis8729]

Sprüh das Auto mal mit Öl ein, sonst rostet der noch mehr

[@VoIPPortland]

My 2014 Promaster passenger side rear emergency brake retainers just decide to come off and jam up to the drum pad causing all sorts of grinding and other special noises. I am not a real mechanic but pretend well. This video was helpful in learning what those pins/retainers are and what they do. No just FINDING them on a weekend is a big challenge. Seems I have to purchase a whole kit just to get retainers. Genuine Mopar Brake Spring Kit - 68095417AA

[@valstedmakes]

Thank you for your comment. I think you can find the retainers and pins alone on Ebay. (Fiat 77364021) But I'm not 100% sure they will fit. Slow shipping and import VAT can also be a problem from Europe. I hope you will find a solution.

[@robertashley7751]

Try putting year in description ffs

[@valstedmakes]

Hi Robert. To my understanding this system is very universal in the X250 series. If you can enligt me you are very welcome and I will add it to help others. Thanks in advance.

[@lilinferno578]

Great video, thanks!

[@valstedmakes]

Thank you. I’m happy you liked it.