This might be a silly question, but with the lower bolt now removed from the mount bracket, can you not then turn in the bolt a few turns, such that it can miss the diff and enable the caliper to then be turned up and over the disc to to the front and then rolled over to the bottom and removed out the bottom?

Good luck

Paul

 

Grab it by the sides, push the top in and up as you pull the bottom out. Make sure that tube doesn't hit anything. You may have to hold that bolt out with a screwdriver at the same time.

 

Just a quick update, I managed to take the caliper out, I had to unassemble it, couldn't do it any other way...
What I have found is that the lower bolt is really on the limit of its size and this makes removing the caliper very difficult, to the point that I wasn't able to do it, probably if I kept wiggling it a few more weeks I might had succeeded
When I put back the new caliper I will take off about 20 thousand of an inch from the head of the bolt... It will be less if I can fit the caliper.
Thanks to all who gave me different advices, all of them were very useful... I know I still have to put everything back together, hopefully I will be able to do it with out any more issues, if not, I know where to find the help that I need.
Thanks again

 

Well done you got there!

Very unusual problem, never come across anything like that before

Alex

 

Congrats on your success, makes one wonder how it was even possible to put in.

 

There is a rib on the differential directly opposite that bolt. If the bolt was hitting that rib and it was preventing the bolt from coming out, then I would think the 1/2 in. difference you pointed out would be a large part of your bolt problem. If I recall correctly, I had to have one of the flats on the bolt positioned to let it slide under that rib to be able to get the caliper out. Please let us know when you find out what caused that. It's very odd.

 

Everything is back together, just need to do the safety wire, but I still have that 1/2" difference (will post a pic tomorrow).
As mentioned before, I ended up shortening the bolt about 1 mm (40 thousands of an inch) mainly from the head of the bolt, I am sure the bolt did not stretch but I think it might have gotten deformed when some one tighten it with an open wrench, the space is so small that it's not easy to tight or loose that bolt and just a slight deformation on any of the flats of the bolt head would prevent from coming out, I was very careful when tightening the bolt this time.

BTW, sorry for such a bad quality on my videos, and kudos to the people who make good content on video and share it on YouTube or other places...

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If the handbrake caliper levels are different it must be because the main calipers they are fixed to are different, or that the mounting holes for the main calipers are different (unlikely), or that the handbrake calipers are different. Carefully measure and let us know where the difference is.