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Replacing Hylex calipers with Shimano?

Old 11-06-20, 04:44 PM
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wgscott
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Replacing Hylex calipers with Shimano?

I have some TRP full-hydrolic Hylex RS brakes. The calipers are the low point, so after several years of annoyance, I replaced them with Shimano BR-M6000 Deore Disc Brake Calipers.

I think I discovered the hard way that TRP's hoses are just different enough from Shimano's that they don't make a good seal. All was well for the first week, but now the brakes are weak, and I in fact discovered a very small but impossible to explain away quantity of mineral oil at the junction of the hose and the front caliper.

So am I just screwed, or is there any way to salvage this? (Anyone else stupid enough to even try to do this?)
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Old 11-06-20, 05:39 PM
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Did you use a new olive on the compression fitting?
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Old 11-06-20, 05:48 PM
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Yes. (On both). I bought the Shimano versions.
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Old 11-06-20, 05:55 PM
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Did you forget the small O-rings on the brake hose bolt?

https://www.google.com/search?client...4dUDCAw&uact=5

https://www.bike-components.de/en/Sh...e-Bolt-p39696/
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Old 11-06-20, 06:01 PM
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I did not in fact use O-rings.

Are they required for the non-Banjo-bolt brakes?

I got the package with these parts (only):




I didn't know they even existed, or were required.

Oy.
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Old 11-06-20, 06:05 PM
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BTW, my kid did the same thing with his mountain bike TRP brakes and these calipers, and it works flawlessly. He says he didn't use O-rings either. (He is now a much better bike mechanic than I am.)

What also worries me is that the TRP hose is 5.3 mm OD, and the shimano is 4.9. Could that be problematic?
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Old 11-06-20, 06:10 PM
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Oh, that's up at the lever! I thought you meant the caliper down at the rotors:



From your picture, I can tell there are other Shimano olives (at least two different shapes). Maybe the shape is the wrong one (hard to know, since you don't use the same "system" throughout.
Also, the olive is meant to take some shape so it fits better when you tighten down the nut so it becomes tight. That's why it is brass (malleable). Did you tighten it enough?
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Old 11-06-20, 06:11 PM
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Originally Posted by wgscott View Post
BTW, my kid did the same thing with his mountain bike TRP brakes and these calipers, and it works flawlessly. He says he didn't use O-rings either. (He is now a much better bike mechanic than I am.)

What also worries me is that the TRP hose is 5.3 mm OD, and the shimano is 4.9. Could that be problematic?
That's a lot of difference for a compression fitting. So, yes, it certainly could be problematic.
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Old 11-06-20, 06:48 PM
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Originally Posted by CargoDane View Post
Oh, that's up at the lever! I thought you meant the caliper down at the rotors:
I did. The caliper is different from the BR-785 pictured (which is essentially XT), and uses a banjo bolt. This one is more primitive, and also has the delightful design feature of no bleed port.

I'm using the TRP hose up to the caliper.



. Did you tighten it enough?
The hope is that I didn't, and it is simply a case of needing to wale upon it some more. OTOH, I wonder if I could have over-tightened it?
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Old 11-06-20, 06:50 PM
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Originally Posted by CargoDane View Post
That's a lot of difference for a compression fitting. So, yes, it certainly could be problematic.
Yeah. That is what I am afraid of.

I wonder if the hose is wider than their mountain one. I will go check it.

Edit: He used Shimano hoses (5mm OD according to my measurement).

Last edited by wgscott; 11-06-20 at 06:57 PM.
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Old 11-06-20, 06:58 PM
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I don't think I've ever used a Shimano brake that didn't use a banjo bolt at the caliper. But since yours doesn't, no you don't need the O-rings. Try tigthening it a bit more to compress the brass. Otherwise, I think it's the vastly different OD tubing.
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Old 11-06-20, 07:05 PM
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Yeah, the plan is now to tighten the living shi'ite out of them, and if that doesn't work, I'm going to install the Di2 ultegra levers (and calipers with banjo bolts and bleed ports) I picked up for $199 from Universal Cycle.
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Old 11-06-20, 07:08 PM
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Good route to satisfaction, WG!
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Old 11-06-20, 07:16 PM
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Originally Posted by CargoDane View Post
Good route to satisfaction, WG!
Except I will have to buy a battery, front and rear derailleurs, and have the frame drilled (or run it externally), or just use them as brakes for now.

It is a touring bike, so I am a bit reluctant to Di2-ify it, but if the situation forces my hand, who am I to ride against the wind?
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Old 11-06-20, 09:07 PM
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Originally Posted by CargoDane View Post
I don't think I've ever used a Shimano brake that didn't use a banjo bolt at the caliper.
My advice is to keep it that way.

They also use the cotter pin that comes with the pads, instead of a bolt.

They were $23 for a pair. I may have cheaped out.
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Old 11-21-20, 05:57 PM
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Originally Posted by wgscott View Post
...
I got the package with these parts (only):




.
This was the mistake. I should have used Tektro/TRP parts. Specifically, the barb thing was too narrow, and also the Tektro "olive" is shaped a bit differently. Tektro's lock nut threads into the Shimano caliper.

The Shimano barb was still loose in the tube when I pulled it apart. I had to tap the Tektro version of it in lightly with a ball-peen hammer. I suspect it requires the tight fit not to slowly ooze fluid. I used the other Tektro parts for re-assembly as well.

It is too soon to declare victory (the other problem took a few days to become apparent), but in retrospect the loose-fitting Shimano barbs should have been a tip-off that they were incompatible with the TRP brakelines, i.e., the TRP hydraulic hose ID > Shimano ID.

Here is what the correct fittings look like:

Last edited by wgscott; 11-21-20 at 06:01 PM. Reason: added second pic
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Old 11-21-20, 06:02 PM
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Originally Posted by wgscott View Post
This was the mistake. I should have used Tektro/TRP parts. Specifically, the barb thing was too narrow, and also the Tektro "olive" is shaped a bit differently. Tektro's lock nut threads into the Shimano caliper.

The Shimano barb was still loose in the tube when I pulled it apart. I had to tap the Tektro version of it in lightly with a ball-peen hammer. I suspect it requires the tight fit not to slowly ooze fluid. I used the other Tektro parts for re-assembly as well.

It is too soon to declare victory (the other problem took a few days to become apparent), but in retrospect the loose-fitting Shimano barbs should have been a tip-off that they were incompatible with the TRP brakelines, i.e., the TRP hydraulic hose ID > Shimano ID.
Yes, it needs to fit tightly. With the better fitting parts, I wouldn't have any worries. I'm certain you won't have any problems with the better fitting stuff. Good to hear you're where you are
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Old 11-21-20, 06:16 PM
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Well, there is still no guarantee that mixing calipers and levers like this will work properly.

But at least now it has a fighting chance. I'm posting this mainly in the event that someone else is stupid enough to try it.
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