E Brake Cable Fun (the wholesome kind)

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by RustOrBust, Aug 13, 2022.

  1. RustOrBust

    RustOrBust New Member

    Joined:
    Aug 13, 2022
    7
    1
    0
    Location:
    Maine, USA
    Vehicle:
    2005 Prius
    Model:
    II
    Good Evening Ladies and Mogwai,
    Hailing from the great state of Maine (where we salt the roads heavily enough that when it snows the lobsters can come ashore to breed), is a wonderful 2005 Prius II with a bit of an underbelly issue. I'm getting myself set up for fluid filming from here on out, but need to deal with a few rust issues before I even get to preventative maintenance.

    Deets:
    2005 Prius
    160k miles
    No major issues (yet)
    Two owners - one Vermont and myself in Maine
    Issues: rust, rockers, e brakes, muffler, rear drums overhaul, brake bleed (likely through Toyota)


    Does anyone have any experience replacing the e-brake cables that run from just above the exhaust resonator down to each of the rear drum brakes, and possibly a few good ideas for drilling/tapping new holes for some rusted-away brackets and bolts? Specifically, does anyone know what the 10mm bolts are so I can look for replacements, and does anyone have any experience drilling and tapping new mounting holes through the frame or floor pan?

    Right off the bat, I realized that all the bolts and brackets that hold the e brake line/cable in place are either going to crumble away when I turn the bolts, or snap. No penetrating lube or heat is going to solve this one. I'm going to have to plan on replacing all the bolts and attempting to come up with a f/ew ideas for (non-welded) brackets to resecure the cable. Any suggestions before I delve back in tomorrow (8/13/22)? Do I need to plan on taking my resonator down, and the heat shield for this replacement?

    Thank you so much if you've got anything to offer! (even comments in jest). I'm trying to work this TANK back into inspection sticker worthy territory.

    Pics included below of the first one I broke off, and more (f**ks were given during this process, I assure you. I didn't just go ham with a 3/4 drive):

    PriusEBrakeBracket1RearPassengerDrum.jpg PriusEBrakeBracket3.jpg PriusEBrakeBracket4Resonator.jpg PriusEBrakeBracket2.jpg
     
  2. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
    2,753
    465
    0
    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    I've lived on Emden pond in Maine spent quite a bit of time up there with the devereaux foundation you are not going to skin this cat any kind of easily that 2005 Prius is taking on rust not so well none of them will I don't have the answers that you want to hear when this would happen to my cars in Western Massachusetts I had family down south believe it or not I would just go down south and grab the car I was driving down south so for instance my 75 Corolla SR5 was strut towers were rotting out etc . I went to Alabama and bought that same car that I left in Massachusetts and it was 12:15 years old but in perfect condition in Alabama and drove it home to Western Mass where I kept it four or five years till the strut towers wore out rusted out. Then I went back to North Carolina and bought a 74 SR5 I like these cars brought it back to Western Massachusetts drove it 5 years I think and then at that time I relocated to North Carolina to pretty much finish up with the rust and snow. But while I lived in New England when my car is rusted out I would generally go down south pick up another car with me it's always been Toyota's in certain series of Toyotas the parts interchange all of that nonsense. Sheet metal screws and all this kind of stuff will not even penetrate this rust it'll go through in the whole screw will go right through the floorboard and be stuck under what's left of your carpet That's how this is going to go. I'm not trying to be crazier or anything I can MacGyver almost anything and rig almost anything according to folks here so I wouldn't even attempt this here to be honest about it I would just take me a weekend and ride down south even now with the cars costing a fortune I'm looking at a Prius right now 07 man's asking $1,500 for it because it needs a battery other than that the car's and not pristine shape but very nice condition if I can get him to 12:00 I'll take the car I haven't even seen it but I know it has no rust and it's never been out of state and it's one owner with 150,000 original miles. Sorry for too much info but you'll wear yourself out trying to do this and I'm not sure who's using the emergency brakes in these things?
     
  3. ChapmanF

    ChapmanF Senior Member

    Joined:
    Mar 30, 2008
    18,647
    12,447
    0
    Location:
    Indiana, USA
    Vehicle:
    2010 Prius
    Model:
    IV
    Everybody who wants the rear shoe clearance self-adjustment to happen?
     
  4. Tombukt2

    Tombukt2 Senior Member

    Joined:
    Nov 29, 2020
    2,753
    465
    0
    Location:
    Durham NC
    Vehicle:
    2009 Prius
    Model:
    Base
    Yep there's that they were Justice will not work without that e-brake cables working but I guess I could live with that I've had to live with that and cars up north it's one of the first things to rush out from the snow right there with the rocker panels in the strut towers.
     
  5. RustOrBust

    RustOrBust New Member

    Joined:
    Aug 13, 2022
    7
    1
    0
    Location:
    Maine, USA
    Vehicle:
    2005 Prius
    Model:
    II
    Hi Timbukt2 and ChapmanF,
    Thanks for the reply. Looks like you and I have similar ideas with getting cars from south of the salt line. This one though I don't have that option to swap out right now (life has its moments), and I'm going to have to get it ready for a sticker. The rust will be fun to deal with, but I'm used to it on cars up here.

    Would you or ChapmanF be willing to look over my plan below?
    Replacing the e brake cable: #1 - spray all the cable brackets and bolting locations under the rear of the vehicle with penetrant, #2 - spray the resonator (exhaust) flange bolts, heat shield nuts, etc with penetrant, let sit overnight (and make a pact with the autorepair faeries), #3 - support the resonator with wooden blocks, and start removing bolts to get above the resonator and heat shield so I can access the "connection point", #4 either drill and tap some some new bolt holes (large washers on both sides, and probably locknuts), or find a different kind of mounting bracket (any ideas?). #5 replace the cable itself.

    PirusEBrakeLines-2004-2009RearDiagramLookingUpUnderTheVehicle.png

    Would something like this work?:
    PirusEBrakeLines-2004-2009SuggestedAlterntativeClipStyle.png
     
  6. RustOrBust

    RustOrBust New Member

    Joined:
    Aug 13, 2022
    7
    1
    0
    Location:
    Maine, USA
    Vehicle:
    2005 Prius
    Model:
    II
    One more potential option instead of drill and tapping new threaded holes for mounting:

    Rivnuts?

    71414.jpeg
     
  7. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    8,560
    3,507
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    "The word "Mogwai" comes from Cantonese and can be roughly translated as "evil spirit" or "demon". Traditionally, they're said to reproduce during the rains." source

    Maybe you can just call us Gremlins instead?
     
  8. RustOrBust

    RustOrBust New Member

    Joined:
    Aug 13, 2022
    7
    1
    0
    Location:
    Maine, USA
    Vehicle:
    2005 Prius
    Model:
    II
    Aye sir. It would probably flow better with "fellow mogwai". Got to love an 80's classic!
     
  9. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    8,560
    3,507
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    That tool looks the same as my rivet gun... Does it do rivets too?
     
  10. RustOrBust

    RustOrBust New Member

    Joined:
    Aug 13, 2022
    7
    1
    0
    Location:
    Maine, USA
    Vehicle:
    2005 Prius
    Model:
    II
    Not this one. The tool uses the threads of each rivnut to secure the piece of hardware in the tool with the arms open. Then as you close the arms it wrinkles / flanges the rivnut around the sheet metal / square stock that you've cut a hole in, almost exactly like a rivet. This an the ridges of the rivnut hold it in place.

    Speaking of rivets, I might just switch over to using rivets. I doubt I'll need to actually use bolts for removal / replacement later, making rivnuts unnecessary, as this set of parking brake cables or e brake cables will likely last the rest of the life of this 2nd gen.
     
  11. RustOrBust

    RustOrBust New Member

    Joined:
    Aug 13, 2022
    7
    1
    0
    Location:
    Maine, USA
    Vehicle:
    2005 Prius
    Model:
    II
    One update from last night:
    Using a multi tool and sawzall to cut off and sand down the existing mounting brackets today after the remaining bolts snapped or crumbled. I'm going to make some new brackets out of sheet metal (old screen door, coffee can, olive oil / paint thinner cans) and rivet them into place with 3/16 long steel blind (pop) rivets. I'm going to paint the sheet metal, and secure it with two rivets so that it won't rotate, and probably coat the whole thing in another layer of spray paint or fluid film. They've only got to last another year or two.

    A note about trying to loosen these bolts with heat (a mini torch), instead of penetrating oil: it seems like the heat makes a difference with rusted bolts. Careful if you use both though since the penetrating oil is flammable.

    BACKSIDE hotwork also needs to be taken into account. Some of these fasteners are attached to brackets that have interior cloth / insulation on the other side of the floor pan. Heating these up (like the ones inside the center "well" where the resonator is) would be a fire hazard on the back side.

    Any thoughts anyone?
     
  12. Mendel Leisk

    Mendel Leisk Underfoot

    Joined:
    Oct 17, 2010
    49,034
    34,967
    80
    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    If someone could come up with a non-corrosive, practical alternative to road salt, they would deserve a Nobel prize.
     
  13. PriusCamper

    PriusCamper Senior Member

    Joined:
    Mar 3, 2012
    8,560
    3,507
    0
    Location:
    Pacific Northwest, USA
    Vehicle:
    2007 Prius
    Model:
    Two
    That's already been done and no one got a prize... Out here on the west coast, we don't use salt, we spray the roads before the snow or ice hits with alternatives. Or as Google explains it:

    "Calcium magnesium acetate and potassium acetate are two chloride alternatives currently available. They are much more expensive than road salt, but if you factor in the loss of wildlife, soil erosion, water quality and corrosion, these alternatives start to look like a real bargain." https://www.mchenrycountyil.gov/home/showpublisheddocument?id=8670
     
  14. RustOrBust

    RustOrBust New Member

    Joined:
    Aug 13, 2022
    7
    1
    0
    Location:
    Maine, USA
    Vehicle:
    2005 Prius
    Model:
    II
    Neat info. I'd only head of people using beet processing waste to ward off ice. However, it would only work down to a certain temp, which wouldn't be low enough for a month or two up here.

    Progress:
    I've drilled out the broken bolt on the wheel/hub frame, right passenger rear side. (Or is this a control arm? What's the right term here?). I didn't have any metric bolts, so I swapped it out with a 1/4-20 1" galv steel bolt, nut and spring lock washer. (Pics below).

    I also found some U channel to cut up for brackets.

    Rear drums have been overhauled including the wheel cylinder.

    Remaining:
    E brake cable reinstall (cut and drill brackets)
    Rear right brake line repair (Does anyone know if I can replace a section of steel line with a section of copper/nickel?)
    Replace the muffler and bleed the brakes (I know... I know...)

    PXL_20220814_234129917.MP.jpg PXL_20220814_234028297.MP.jpg PXL_20220814_234139874.MP.jpg
     
    Mendel Leisk likes this.
Loading...