Help please. Can somebody tell me how to remove and replace the release button and spring on the al-ko handbrake on a ‘91 Puck? The existing button is falling apart. I have already got the replacement parts but now I’m stuck! Thanks

I don't know about the '91 handbrake. Is that a black grip and button? I recently changed the grip and button on my 2005 Triton (maroon handle and button - AL-KO) and the handle was a push fit. However I had to cut mine off because it did NOT want to come off. Once cut off I could see that the button and spring were retained by the shape of the moulding in the push-on grip. Luckily I managed to find the button and spring that had fired off when the outer finally came away.

Thanks for that. I think the grip and button may have been maroon originally but after years in the sun, I suspect, they are a kind of degraded pink!. Sounds as though mechanically it’s a bit different. The handle is certainly a push fit (the old one had completely cracked and fallen apart) but the button (also cracked) and spring are still in place and are reluctant to move. Maybe I’ll just fit the new grip and will have to live with the old button?!

Could you post a photo? Close up, ideally?

1688459414912.jpg - Bild entfernt (keine Rechte)1688459414919.jpg - Bild entfernt (keine Rechte)
Not brilliant pics I'm afraid but I think they show the set up. Button and spring function perfectly well but don't want to come out at all. I'm guessing that they're held in place by that pressed 'dimple' on the side of the handle. There's an identical one on the opposite side. Normally they would be hidden under the plastic grip of course. Maybe the button and spring are intended to be integral parts of the brake handle and are not replaceable items?

It would be a brave company that expected a plastic component to be a lifetime item. It looks to me that the spring is firmly attached to the knob and the spring is then crimped in place by that dimpled impression lower down the handle. It seems to be impossible to find an exploded view of those parts, so, maybe, AL-KO did, actually, intend that to be a lifetime part!! the 2005 version on my Triton didn't look like that when I removed it to change it.

I think I have found the right handbrake assembly, but only available as a complete assembly.

Yeah, I’m pretty sure that’s the right assembly. Maybe in due course if the button completely fails that will be the only solution. Until then I think I’ll just fit the new grip and cross my fingers. Thanks for your help.

Have you tried to unscrew it.

Not tried myself as yet on my 92 puck. Lots of plusgas/wd40 protect button with cloth from grips and see if it unscrews

Phillip

Edit you can purchase button and spring so must be away to change them.

perhaps supposed to prise the underneath seam open if does not unscrew.
what does the new button look like?,
perhaps can suggest something if see, what cannot see behind the metal in pictures

may be need to replace arm for the button. Id choose the easiest solution for yourself.

https://caratechcaravanparts.com/product...and-spring-1088

Says button screws on and off

And , as it's clearly perished, it will probably shear off flush if you try and unscrew it. Not being pessimistic - just realistic! Always best to get a replacement part first and study it to see how it comes apart...

Hi all, and sincere apologies for not having picked up on these more recent posts earlier. Drandad and Caratech are right - it does indeed unscrew - and, luckily, the old one was not so badly perished. Plenty of WD40 and it eventually shifted without the use of any tools, just a firm grip. Thanks again for the help.

Is there a forum setting that I have missed which automatically notifies me of new posts in a thread that I’ve started?

Have a good day,
Martin

You're welcome Martin.

Nice to know your refurbishment job was a success.