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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,101
Thanks to God, everything is Successful !!!

SUCCESS!!!

I've never drove a vehicle with such braking power, using little pedal force to completely stop, in a straight line; no matter if the road is paved, gravel or unpaved road.

Finally, the KiaStein features the awesome Braking system that I always wanted, it doesn't lock the wheels easily, and lets you maneuver correctly, during panic braking.

And the Best part: my Wife is Happy with her car's Behaviour.
Thanks to God.

Kind Regards.
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,102
So, this is the way to go: if you swap rear disc brakes on your second gen Sephia / first gen Spectra, those will be 10.1" so you Must swap the front disc brakes from the donor car also, in order to have same sized 10.1" front discs too, not the lousy 9" in front ... the Brakes works Awesomely with 10.1" all around in the four corners.

Don't touch the master cylinder at all. :shades:

Kind Regards.
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,103
Still I believe that the Brake Pedal on this second gen Kia Sephia, is a little high placed from the floor, so the approach with the foot is more with the toes than with the mere foot as in other cars... and I use 12W shoes; my wife use 8 shoes, so it is even worse for her.


I believe that Braking Behaviour could be improved even more, gaining less foot effort, if the Brake Pedal were placed a little lower...

...but that, is Another story.
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,104
Maybe this issue was a li'l more noticeable to me, as I suffer from Genetic Gout Foot Attacks from time to time (More info, ~► Here) So, I decided to go back to the 2004 Spectra donor car at the Junk Yard, and grab (among other things) its brake Pedal, in order to modify it, saving the original one as backup to place it back on the car, if things goes wrong...


 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,105
I drove many, many different cars, vans, trucks, SUV's, etc, since long years ago; and ALL of them had a brake pedal that is placed in a way, that you can easily (and Safely) reach it with the Foot, not with the Toes; only the second gen Sephia / first gen Spectra (same car, almost) on Automatic versions, suffer from this short pedal issue; which really affects the braking feeling / behaviour and safety on these models.

So I decided to cut the Kia's brake Pedal bar, close to the pedal itself; and cut a little more than an inch from an old Toyota's brake pedal bar, which I found at a friend's pile of old parts... then I carefully welded the Toyota's metal bar piece, to the Kia's metal bar; as you can see on the followin' Photo:




The old 'yota's metal bar is much thicker than the Kia's one.​
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,106
This is how the extended pedal looks, after a layer of anti rust paint:




and after the second layer:



Ready to be placed on the "KiaStein"​
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,107
Awesome!

Here's the extended Pedal, already installed and tested:



The brake pedal was placed from factory, almost at the height of the accelerator pedal's top; now that it has been lengthened, the brake pedal has lowered and is located at the height of the center of the accelerator pedal.

The extension not only lowered it, but also it came out a little, resulting in a brake pedal slightly higher and much better located.

The results of this small modification, are so Awesome, that I really wonder why the heck I didn't it Before, because I noticed this issue since I obtained the car, in december 2009
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,108
By the way...

The added metal to the brake Pedal, isn't noticeable,

unless you bow down to see it :thumbsup:
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,109
The added length to the brake pedal, not only makes more comfortable and safe to reach it; but also got some additional leverage on the brake pedal, which translates to more force being input to the brake master cylinder with the same foot/leg force exerted on the brake pedal; in fact, as the pedal got the extra length, also it came out to the front a little, which allows me to move my seat one notch farther, reaching the Brake pedal safely; which makes the overall feeling of driving the car, way better.

I hope that the information and ideas I share here, could be helpful for more people.

Kind Regards.
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,110
Sigh

I know that this is an almost Monologue that I have here, and that nobody cares about my story anymore; so I'll update with only the more important things I've done to this 2000 Kia Sephia, worldwide known as the "KiaStein" hoping that maybe, somehow, someway, someday this information could be useful for more people...
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,111
Four Problems

Sometimes, circumstances collide to make you face problems in group, not one by one as usual... this time, the Bushings for the control arms, decided to give up, and the "KiaStein" started to develop annoying ´Clack´ noises, when first departed from parking, or when first moved to reverse.

Also, the Air Conditioner system developed a Leak after all this years of flawless performance blowing icy cold air... which my Wife really enjoys ...I don't really need air conditioner, until it starts to rain and the front windshield gets foggy... so, somehow that feature is a must have here, in the Tropical area of the world.

Also, the exhaust system developed a couple of leaks that make the T8D engine on the "KiaStein" to sound loud and rough, and both leaks were just next to the exhaust manifold.

Finally, the old leakage on the Power Steering Rack, became even worse, and needed attention...

Despite that, this noble car still worked great, on and off road every day; but now was time to get my hands on it, and solve all those problems, in the very best way I could.
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,112
Honduran Junk Yards

In the past, I mentioned that Honduran Junk Yards (called here "Yónker" in singular, and "Yónkers" in plural) brings cars cut in halves from the USA; mainly their front clips, are sent inside containers on merchant cargo vessels...




...You can find many separated parts from cars...





...and many front clips from various cars...





...Stacked on metallic buildings...


 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,113
In one of the many, many "Yónkers" here, short time ago; I found in a front clip of an early 2004 Kia Spectra with only 31,000 miles; this things:

► the Complete Hubs.
► the Rotors.
► the Calipers.
► the Disc Pads.
► along the Axles.

...and I did a complete retrofitting of those parts onto the "KiaStein" in order to upgrade the front brakes, from 9" to 10.1" and also upgrade Axles to the beefier ones; you can see photos and read info regarding that subject, in previous posts of this mere thread.

So, after all these problems appeared, I went back to that "Yónker" and found the same front clip still there, which had almost all the parts I needed to solve the problems.


 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,114
Puente (Bridge)

So, I purchased this other parts:

► the Engine's Crossmember.
► both Control Arms along their Bushings.
► the Ball Joints.
► the Power Steering's Rack.
► along the Tie Rods.

By the way, in Honduras, the engine's Crossmember is called "Puente" which means Bridge.



I obtained everything as a Complete Assembly from factory, it came with everything underlined in yellow on the Photo, plus the power steering's rack, pointed by the yellow arrow; and they included the anti-roll bar (Stabilizer bar) to sell me the whole assembly.
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,115
I borrowed a couple of movable car ramps, made by a local mechanic friend; and raised on them the "KiaStein" in order to extract the whole set, of crossmember, power steering's rack, control arms and stabilizer bar, etc...





...with the idea of installing there, the complete set from the Spectra 2004, instead.​
 

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1985 Subaru Loyale (wagon), 2000 Kia Sephia (sedan), and 1969 Mercury Comet (coupé)
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Discussion Starter #1,116
Meanwhile, it was way much easier to address the leakages, on the Exhaust piping and on the Air Conditioner system. Firstly, I started with the simplest thing, the Exhaust Leakage.

I found two leakages in fact; the mean leakage was on a fissure at the pre catalytic converter's assembly, which was gutted by me, several years ago (More information ~► here)





The other was a minor leakage, found on the flat metallic seal at the other end of said assembly:




The main leakage was resolved with a thick and strong weld bead around the piece; the minor leakage was resolved by simply smearing a layer of "Mega Grey" Silicone on both sides of said flat metal seal, and also on both metallic surfaces (the exhaust manifold and the gutted pre-catalytic assembly) and Voilá :thumbsup: first problem, Solved.


 

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Discussion Starter #1,117
Next, to address the leakage on the air conditioner system... it was way more difficult; in fact, as I failed, I had to ask the help from a local expert, who using the special tools and equipment, firstly inflated the system with air and then searched for the leakage in every inch of the pipes, hoses, joints, etc... and finally he found it.

The leakage was inside the Compressor, you can hear the hiss of air escaping from it when he manually turned it, on the following video:


 

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Discussion Starter #1,118
The next step was to remove the Compressor from the "KiaStein" and completely disassemble it, in order to check it from inside out, and fix it, if possible.

What he found, was that everything was alright inside the Compressor, especially for one that is almost two decades old and has over 250,000 miles; the only worn out part, was the round seal, that is often known as the "O-Ring" which in fact, is a metal ring with Rubber on the inner side, that rubs against the spinning axle of the Compressor, preventing the r134a gas, from escaping; it was completely worn out, with the rubber stretched; due to age and usage.

So, in order to obtain a brand new seal Kit for that compressor, I had to travel to Capital City on my Beloved Subaru "BumbleBeast" and search for a suitable seal kit, according to the sample I carried with me.
 

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Discussion Starter #1,119


Interesting is that they placed a sticker with the Engine model of the car, T8D, on the Compressor.


In the following photo, you can see both seals together:





The Photo below, shows the Seal Kit, along the old worn seal:



Seal Kit Nº SS-0731

Found on a professional air conditioners & supplies' store


 

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Discussion Starter #1,120
Finally, I Had to purchase three cans of r134a gas and one can of the appropriated lubricant oil for the air conditioner system on the "KiaStein" and...





...Voilá! :thumbsup: another problem, Solved.​
 
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