Any ideas of how to route a new parking brake cable through the chassis (right side)?

Tiny
CHRISTOPHER SA
  • MEMBER
  • 1993 BMW 320I
  • 1.9L
  • 6 CYL
  • 2WD
  • MANUAL
  • 120,000 MILES
I have had to rebuild the entire rear right suspension in that a new (used) trailing arm, lower wishbone, suspension spring (the one on there was broken!), Bearings, hub, rotor, brake pads, parking brake pads, parking brake cable and complete output shaft (as the CV joint wouldn't move freely) had to be replaced. This was due to discovering that the prior owner had hidden the damage done from an accident that most likely happened in this area as when putting the bolts back in for the upper and lower wishbone to the trailing arm the holes wouldn't match. It was impossible to install the bolts back. Hence why the entire rebuild of this area.

Everything has been done apart from the parking brake cable being reinstalled. It has been installed at the hub end and attached to the parking brake shoes, but when trying to route and snake it back into the chassis so that it can be attached to the handbrake, it is impossible to put back.

The length of threaded rod goes into the hole where the cable originally exited the chassis, but it goes no further and there is approximately 18" of cable left to thread back in.

I have been trying to find any information about how the cable gets to the handbrake, looking for diagrams of where the cable goes (after entering the hole) and what, if any, obstacles there are to getting this done.

I am doing this in a garage and have one side of the car up on a jack stand with the left side wheel on the ground. I also have a 3-ton hydraulic jack that I can use if necessary.

I have found that working under the car gives me limited room and it's very uncomfortable under there.

Am I going to have to remove the exhaust and heat shield to do this job?

Any help would be very greatly appreciated. This car is also the same mechanically (suspension-wise 90%) as the 323i and 325i (manual).

As a side note, I am extremely mad at the engineers who designed this car as all they had to do was put a metal tube in place which allowed the cable to be pushed through all the way to the handbrake so it could be done smoothly. But no! Typical of engineers everywhere (who design absolute crap vehicles nowadays - in terms of making it easy to work on cars) they left this bit out to make it extremely difficult to do a very simple job.
Wednesday, March 6th, 2024 AT 12:01 PM

14 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,813 POSTS
Hi,

The 320i wasn't offered in the US this model year. I'm showing a 318i and a 325i. The information I have for both is limited to replacing the cable and doesn't show a point of entry.

By chance, could you upload a few pictures of what you are dealing with? I may have a suggestion or two. Also, I attached the directions for replacing the cables on a 1993 318i below so you can see what I have. I noted that the directions for the 325i are basically the same.

Let me know.

Take care,

Joe

See pics below.
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Wednesday, March 6th, 2024 AT 7:09 PM
Tiny
CHRISTOPHER SA
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I'll get the pictures done tomorrow.

I had to do extensive modifications to the new cable at the brake shoe end (see images) and I have just had a thought that maybe I need to file down the metal at the base of the threaded rod as it is slightly 'fatter' there.
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Wednesday, March 6th, 2024 AT 8:11 PM
Tiny
CHRISTOPHER SA
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Here is the video of what I am up against. Was I meant to push into the hole in the chassis (that is shown at the beginning) the hand brake end of the black cable (with the metal bit) first?
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Thursday, March 7th, 2024 AT 3:56 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,813 POSTS
Hi,

I would think that is how it would have to be done. Are you able to run a piece of mechanics wire from the inside through the chassis to where the cable is located? If it is a problem with the cable stopping before it fully enters, you may be able to guide/pull it through.

Let me know. Also, does the attached pic appear to be the same as what you have?

Joe

See pic below.
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Thursday, March 7th, 2024 AT 5:31 PM
Tiny
CHRISTOPHER SA
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  • 236 POSTS
Yes, that is how it is at the hand brake end.
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Thursday, March 7th, 2024 AT 5:46 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,813 POSTS
Is it possible to use something like mechanic's wire to fish it into the vehicle?

Joe
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Thursday, March 7th, 2024 AT 5:56 PM
Tiny
CHRISTOPHER SA
  • MEMBER
  • 236 POSTS
What exactly is mechanic's wire?
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Friday, March 8th, 2024 AT 6:41 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,813 POSTS
Hi,

It is a wire that is smaller in diameter and flexible but ridged enough to work its way through things. I attached a pic below.

Let me know.

Joe

See pic below.
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Friday, March 8th, 2024 AT 7:58 PM
Tiny
CHRISTOPHER SA
  • MEMBER
  • 236 POSTS
An update.

Yesterday, after over a week of trying to get this cable fitted with no luck, I discovered what the problem was the wrong length of cable and the wrong length of the threaded end! See images for a clear explanation.

The end with the thread was 0.5" too long which prevented it from moving around the curves in the tube that went to the hand brake. The tube went from the top of the transmission tunnel, along it for little ways, then curving over to the top of the tunnel to the hand brake. That extra 1/2 an inch prevented it from moving around those curves. And that is why it wouldn't go in beyond a certain point!

I also have a video of the tube itself, as I purchased an endoscope to see what the heck was going on inside the tube/chassis, which I will post soon. But that threaded end was long enough to prevent it moving through those curves. Needless to say, I am getting a refund on the eBay item and have ordered a new cable locally which I will be picking up on Thursday (tomorrow).

Note: The original cable looks in better condition than the new one. The original was rusted into the hub end and the plastic had cracked at the juncture between the metal ferule and the cable. So, I went ahead and tried replacing it.
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Wednesday, March 13th, 2024 AT 8:57 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,813 POSTS
Hi,

Wow, you have the same kind of luck as me. LOL I just got this information from you and its already Thursday night. Were you able to get the new one installed?

Joe
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Thursday, March 14th, 2024 AT 7:37 PM
Tiny
CHRISTOPHER SA
  • MEMBER
  • 236 POSTS
Nope. The place I had originally ordered the cable from locally for pickup on Thursday had the wrong cable delivered again. So going to the local BMW dealership I found that the price for a new brake cable was very close to local aftermarket parts prices and has a policy of delivering stuff ordered after 1:30pm on Thursday, on Monday (they don't have it in stock so have to order it from their main HQ).

So, I am going to do all the work on the other 3 wheels (which I had been meaning to do as I have purchased the parts already for these jobs - hubs, wheel bearings, splash plates, rotors, and pads) while I wait for Monday to come around. I will update you on how the brake cable installation goes on Monday! By then I should have the video of the brake cable tube that the brake cable goes through ready to upload.
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Friday, March 15th, 2024 AT 5:48 AM
Tiny
JACOBANDNICKOLAS
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Hi,

Thanks for the update. You have your hands full. Take your time and I look forward to hearing from you.

Take care,

Joe
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Friday, March 15th, 2024 AT 6:40 PM
Tiny
CHRISTOPHER SA
  • MEMBER
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I finished all the work on the suspension/wheels on all four corners but here is the video dealing with the parking brake cable which was so easy to install!

In the end, the correct cable made it a 5-7 min job not a two-week job! I got a refund from the seller of the wrong cable. Shame I had to go through so much time and expense to figure out what was going on.
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Saturday, March 23rd, 2024 AT 3:15 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,813 POSTS
Hi,

Thanks for the update. I'm glad you got it back together. Having the correct parts does make it easier. LOL

Regardless, thank you for the video. It will likely help others in the future. Also, feel free to come back anytime.

Take care,

Joe
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Saturday, March 23rd, 2024 AT 7:06 PM

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