Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20839
How To - EPB repair/Unjam + Relatch
How To - EPB repair/Unjam + Relatch
Had a few of these in lately from other garages, all with condemned EPB modules...
All modules failed to unjam themselves using the diagnostic machine. All these modules were successfully unjammed manually, and all to date are still working, with no issues
If your module sounds like this: http://www.youtube.com/watch?v=fcV6vCnib9o , Read on!
From what I can gather, the main issue stems from poorly adjusted shoes, or the lever arm on the shoes have been seized, the motor has wound the threaded rod to its full extent of travel, and jammed itself. It then will not release, and the emergency release cable has to be pulled, and will not relatch itself...
This guide is not a guaranteed fix, but every one so far has been successfully repaired. The module will re-jam again, if the underlying issue is not resolved, so it is always worth removing the discs and inspecting the condition of the shoes
Anyway, locate EPB module above rear diff. Also a good time to inspect the front-rear brake pipes, as this is where they rust, as you can see from the picture
Click image to enlarge
Remove 8 T20 screws, and prise cover off the front of the module (only 7 in this picture) The cover is well glued on, and requires perseverance, and patience to remove:
Click image to enlarge
This is what you will be confronted with:
Click image to enlarge
The silver part in the middle is the motor, which turns gears inside the white plastic housing, which turns a (what looks like) Brass rod, and tightens and releases the cables. The small white plastic item at the lower left pulls the drivers side cable, and when the emergency cable is pulled, it unlatches itself from the metal part to the left of the large white plastic housing, which is in turn attached to the passenger side cable.
As you can see from the picture, the brass rod has fully extended, and jammed, and the small white plastic box it not latched to the other cable
The brass rod needs to be turned downwards (looking from the passenger side (on a UK car), it would be turned anti-clockwise) to unjam it, and unwind it. Once unjammed, it can be wound back using a diagnostic computer, or manually using a small lever or screwdriver. This picture is approx half way:
Click image to enlarge
Here it is almost fully unwound. You can clearly see the brass rod unwound on the threaded rod:
Click image to enlarge
Once you are happy you have unwond it enough, push the 2 side of the cables together to relatch. Compare the metal parts to the right hand side of the small white plastic box between this picture and the next:
Click image to enlarge
All done:
Click image to enlarge
Now, put the EPB shoes back together, discs on and adjust as normal. Operate the EPB switch, apply and release a few times to check for correct operation. Once happy, re-adjust shoes again to ensure the adjustment is OK. Once you are happy the EPB functions correctly, clean as much of the old silicone off the EPB module and cover as possible, reseal with some silicone sealer, and refit the screws.
All being well, you will now have a fully functioning EPB module, and saved yourself close on £500 for a replacement module, and another few hundred quid in labour
Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated My D3 Build Thread
Last edited by Disco_Mikey on 5th Jun 2019 4:52 pm. Edited 7 times in total
25th Feb 2013 9:15 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20839
If anyone needs any clarification on any steps, let me know, and I will do my best to explain, and hopefully update the 1st post. It makes sense to me, but I have done this repair enough to make sense to me My D3 Build Thread
Member Since: 13 Sep 2008
Location: Midlothian
Posts: 920
Epb
Hi mikey
Good fix but if the epb module has been causing problems over time it will have damaged the toothed wheel on the motor
I completely dismantled mine when I did the replacement just to see why it had failed and found that it had worn the teeth down on the big plastic wheel.
I also found that the failure of the epb was probably caused by the previous owner or servicing garage not bothering there to strip, clean and lubricate the adjusters on the shoes and as you know this probably caused the problem in the first place
Cheers
25th Feb 2013 9:59 pm
Robbie
Member Since: 05 Feb 2006
Location: ¯\_(ツ)_/¯
Posts: 17932
But worth a look inside before buying a new one I should think.Land Rover - Turning Drivers into Mechanics Since 1948
Member Since: 09 Jul 2011
Location: Central
Posts: 1790
yet another top tip Mikey!
25th Feb 2013 10:31 pm
Oswiperus D3 Decade
Member Since: 02 Apr 2010
Location: Chelmsford, Essex
Posts: 1599
Another great guide Mikey, although hopfully i won't need this one as i keep my shoes cleaned, lubed and
adjusted(thanks Bodsy). I doubt i would've tackled the cam & pump belts without your guide. Those who
create guides or just give advice on this forum make it a great place to visit.
I like the jokes too!
Stu
25th Feb 2013 11:09 pm
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20839
Re: How To - EPB repair/Unjam + Relatch
Disco_Mikey wrote:
This guide is not a guaranteed fix, but every one so far has been successfully repaired. The module will re-jam again, if the underlying issue is not resolved, so it is always worth removing the discs and inspecting the condition of the shoes
MikeS2005 wrote:
Hi mikey
Good fix but if the epb module has been causing problems over time it will have damaged the toothed wheel on the motor
Robbie wrote:
But worth a look inside before buying a new one I should think.
I would rather have a go myself, before commiting to a new module. A new module + fitting will not be far off £600 + VAT, before you get to the main issue of what has caused it to jam in the first place. By the time you add on the cost of new discs, pads and EPB shoes, you could be facing a bill of around £1000.
Catch it early enough, you may get away with just a strip and clean of the EPB My D3 Build Thread
Member Since: 03 Jul 2009
Location: Glasgow
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I couldn't see the bit about pushing the two sides together where it says compare the pictures? I just thinking for future reference Joined the BMWX5 45e group
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26th Feb 2013 7:12 am
Gareth Site Moderator
Member Since: 07 Dec 2004
Location: Bramhall
Posts: 26772
I think Mikey meant to say "Compare the metal parts to the right hand side of the small white plastic box between this picture and the NEXT: instead of "Compare the metal parts to the right hand side of the small white plastic box between this picture and the previous:
If you look at the metal piece next to the small white box with the QR code on it, it is closer in the second (or last) picture.
26th Feb 2013 8:09 am
Disco_Mikey
Member Since: 29 May 2007
Location: Dundee, Scotland
Posts: 20839
Gareth is correct. It is difficult to see the difference My D3 Build Thread
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to strip, clean and lubricate the adjusters on the shoes and as you know this probably caused the problem in the first place
