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  1. #1
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    Broken Shimano BR-M445?

    Took a spill today on the trail and the upper piston/plunger popped out on the brake lever. I was able to pop it back home and went immediately home as I wasn't sure how everything would be affected. I've attached photos of both brake levers. The one that came out is missing what looks like a washer and c-clip. Anyone know if I can get some replacement parts and if this is repairable? It seems like something I could even possible get off McMaster or something.

    The bike is a 2012 Cannondale Trail SL3 26"
    The lever is a Shimano BL-M445.

    The tech sheet doesn't give any specs so I'm guessing I'm SOL on this one...
    Attached Thumbnails Attached Thumbnails Broken Shimano BR-M445?-ok.jpg  

    Broken Shimano BR-M445?-notok.jpg  


  2. #2
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    Given that this is the base model lever, it may be more cost effective to just buy a new lever and re-bleed the system. By the time you get the relevant clips, washers etc, you could end up paying more than the lever is worth.
    Could be a good excuse to upgrade

  3. #3
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    Quote Originally Posted by oregoncurtis View Post
    Took a spill today on the trail and the upper piston/plunger popped out on the brake lever. I was able to pop it back home and went immediately home as I wasn't sure how everything would be affected. I've attached photos of both brake levers. The one that came out is missing what looks like a washer and c-clip. Anyone know if I can get some replacement parts and if this is repairable? It seems like something I could even possible get off McMaster or something.

    The bike is a 2012 Cannondale Trail SL3 26"
    The lever is a Shimano BL-M445.

    The tech sheet doesn't give any specs so I'm guessing I'm SOL on this one...
    Yup Shimano does not sell replacement parts for the brakes it is either warrentied or you have to replace....

    If you have a good hardware store (metric) you might find some replacment parts there....I would upgrade.

  4. #4
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    What should I upgrade to? Deore XT? I was pretty happy with the performance of the branded one's so far.

    I'm hoping to take it to the shop and see if I can get it replaced under warranty as I've only had the bike 2 weeks.

  5. #5
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    Quote Originally Posted by oregoncurtis View Post
    What should I upgrade to? Deore XT? I was pretty happy with the performance of the branded one's so far.

    I'm hoping to take it to the shop and see if I can get it replaced under warranty as I've only had the bike 2 weeks.
    Oh yeah if the bike is that new they may very well just replace it for you that is the place to start....

    XT is a very good choice.....so is what you have for that matter

    I thought the bike was much older for some reason.

  6. #6
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    Good news. I was able to salvage the retaining ring and found a replacement washer at work. Unfortunately it's not the exact correct size, nor the correct material (zinc plated steel vs. SST). It does fit though and I've taken the bike on a short ride and everything seems good. I had to remove a little brake fluid as the washer keeps the ball joint pushed in a little further than if I had the correct washer.

    For anyone curious the correct washer size is what looks like an M4 x 12mm OD x 1mm thick washer. I used a #8 washer which is a little thicker and has an OD of about 11.5mm.
    Attached Thumbnails Attached Thumbnails Broken Shimano BR-M445?-parts.jpg  

    Broken Shimano BR-M445?-fixed.jpg  


  7. #7
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    You could always flatten the bad washer. I did that to a set of Hayes I bought used. The washers became conical after so many uses. I just flatten it with a hammer and they slid right back in.

  8. #8
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    Believe me I tried. It's pretty hard material.

  9. #9
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    hydraulic press?

  10. #10
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    use Dremel, small drill & some Dremel bits...cut the top head to fit a screwdriver, then grind down the bottom rivet head...boom, remove the washer and pivot pin..boom... use existing broken lever as a template, make your custom DIY lever..fit...make a pin or do your ghetto BUT Never create pressure on the Yoke portion of the lever body...else the body is cast aluminium product you can easily break the pivot hole mounting area.....enjoy

    Broken Shimano BR-M445?-shimano-alivio-m445-disc-brake-lever-set-black-ev202104-8500-1-copy.jpgName:  100000236.jpg
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    Last edited by Hill Storm; 05-28-2017 at 11:50 AM.
    Enduro

  11. #11
    RAKC Industries
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    FYI it's only $30 to replace the entire lever/hose/caliper all together.

    Not even worth a DIY solution IMHO for that price though just a simple washer and clip the OP did is obviously easy. I wouldnt trust it as a front brake though.

    Sent from my XT1565 using Tapatalk
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  12. #12
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    Hello 5 y/o post...
    disciplesofdirt.org

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    We get old because we quit riding.

  13. #13
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    Lol I didn't even notice.

    Sent from my XT1565 using Tapatalk
    Life on a bike doesn't begin till the sun goes down.

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  14. #14
    Enduro Tourer
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    yah..indeed...but still, sharing info is good..isnt it? this ghetto/old school tech helps us later...and u/me can afford a slx/xt but there are ppl who still use 315/355/365/395 brakes and those 500$ bikes are huge in numbers..so there are people who look for a solution , this can help m
    Enduro

  15. #15
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    Quote Originally Posted by RAKC Ind View Post
    FYI it's only $30 to replace the entire lever/hose/caliper all together.

    Not even worth a DIY solution IMHO for that price though just a simple washer and clip the OP did is obviously easy. I wouldnt trust it as a front brake though.

    Sent from my XT1565 using Tapatalk
    Some people don't like to throw things away that are only two weeks old.
    I wonder if he still has it.
    I'm sick of all the Irish stereotypes, as soon as I finish this beer I"m punching someone

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