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How to rebuild brake calipers.......w/pic's
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02-06-2011 10:39am#1OK, as I've just been through the mill on this myself, please find my 'how to' on rebuilding brake caliper's.
Now, the big caveat's first:
1. These are brakes. They are your life. You do not take short-cuts.
2. If you have any doubts about your abilities, don't. By all means go to a scrappy and get a caliper and practice - if nothing else, it'll help you understand how they work, and why they need to be maintained. If that works out well, carry on. If it doesn't be glad that the next time your mechanic does it's probably well-earned. (particularly if stripping it involves stubborn/seized/corroded bits).
Smaller caveat's...
3. These are Brembo 4-pot calipers, from a Porsche. However, Brembo brakes are fitted to a whole range of cars, the usual supercars, but also the likes of WRC-inspired stuff (EVO's etc). Even outside of Brembo, the general principles in terms of pistons, seals etc, are common. Thing's like actual brake pad clips, pins etc may vary.
4. No warranty given or implied.
Now, on the car, calipers tend to look like this to you............hence why mine needed a rebuild.
Here we go......
First, you'll need tools. Not a lot, mind, but you'll definately need some.
And, some of the most useful are the cheapest - pick tool set - €7.00 iirc, and so on. A compressor is a big help (to pop pistons out).
And, you'll need the galwaytt BIG RED caliper..............holder !
What's that for, I hear you say............ah...............thought you'd never ask...........
it also allows you to flip it on it's back......
So, start here (calipers off the car, of course.......... :57: )
Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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ok, the reason for all this palaver is the dreaded 'Plate Lift', so we need to strip the calipers completely. Plate Lift is where the stainless steel plates the pads sit against, get 'lifted' out of the caliper, by corrosion of the aluminium, underneath.
With pads out, you can see the 'furry' corrosion on the calipers in the right and left hand corners......truly awful
Armed with trusty pick tools.......er, pick the dust seals out.....
Oh, and yeah - the red stuff IS what you think it is........sharp tools them picks.......
Once done, and pistons out, I needed the link pipes off, and they needed persuasion, believe me........
Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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Corrosion, and carnage, up close......
Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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...I covered them with paintstripper - twice.......
and even after that, they 'appear' ok..........
Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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..but more........TLC........required..... >:D
so, my setup is like this:
and it's off to work with the magic tool.......
....getting there.....
....much better.....
...might as well do the rest, so......
....and after 2 hours, we end up with this......
Nothing else to report until after they get painted, so I'll revert, then.........Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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1. First, get some of these made: fake pistons. Allows me to sandblast and paint the calipers, without wrecking threads or bores.....
snug fit:
2. Fit as follows:
3. all those extra M6 bolts allow me to pull the pistons, without resorting to levers, and wrecking the paint......
That's it for now, more, anon.....Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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First, paint - in the end, I bought brake caliper paint and did it by hand - all things considered, I'm happy with it, but it's a messy old job, no two ways about it......
I thought I had a pic of them just after painting.......but I don't, so on with the next bit.......
First, hoik out the old piston seals, using suitably sharp instrument (see 1st post.......)
And then - important this - do a 'dry run' of assembly, with the new s/steel screws......you don't want to find you've a problem when you're doing it for the final time, with goo's and glue's all open..... Well, I don't anyhoo.
Earlier, I had taken the old dirty caliper plates, thus:
and, using the miracle that is Pickling Paste, turned both them (and the caliper retaining clips), into this.....
Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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...then, taking you're time, with all your new parts lined up in front of you.......start Le grand Re-assemble......
A finger of special grease on all the piston seals, and they all go in, within seconds with no fuss.
Then, take each new piston in turn, apply a bit of the same special grease ......
...push each almost home (but not quite..........more on that later........) they should go in with nothing more than a firm push...if you're wondering how I have 2 hands in the pic......and who's taking the pic's........step up Robert, aged 8.......and the Sony Ericsson W995 camera phone......
Then on to Dust seals (easier if you leave the piston's proud, see...........)
Smidge of grease on the inside......
fit the seal over the piston...........
and then push the piston home, and then the dust seals into the caliper grooves....and it should - SHOULD - look like this.....
Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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Now, there is a school of thought that says to prevent future plate lift, to coat the back of the plates with copper paste or similar, and another that says to actually seal it with high temp Silicone.
Me, knowing the hard life that pressure washer's, wheel cleaner's, and ****e on Irish roads generally, I've gone with the silicone. How high temp ? 315 deg intermittent and 260deg cont duty. Brake fluid boils at 230 anyhoo, so we're well covered....
So, smear the plate(s) with goo......
...and offer up to the caliper........they're a bloody tight fit btw...........and foul the dust seals as well.......****e design.....and don't forget to put Loctite on the retaining screws (corrosion issue)
Re-fit caliper retaining clips, etc, and it should look like this.......
and the new decals, thus.......
And you should end up with something like this............
Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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The finished, fitted, article.........
Proof of the Pudding ?
This
:
So Endeth The Lesson.
Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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Question: What is the "special grease" that you are using on the seals and pistons?
Ah - you're the 2nd guy to ask that. With great difficulty, I tracked down Castrol Red Rubber Grease, and the only people that had it was Walsh Oils in Cork 021 4314588.
So, I lined up all the packets of new pistons/seals etc......and then found a sachet of it in each packet of pistons !!! Doh !! (apparently, they do that as standard ........ )hey man, i know you from a few other forums (vespaclubofireland etc) can i use your guide to rebuild my px MY grimeca disc caliper with more a less the same steps?
Knock yourself out Have all the bits before you start - including new 'banjo bolt' sealing washers for the hose connection (don't re-use the old ones).
As far as I know - all calipers use the same piston and dust seal arrangement, and have done for yonks......a bike caliper should be much more straightforward, as might be a 'sliding' type, which means it only has one piston !Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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Cool thanks for that.
I use DOT4 brake fluid to lube the seals on my Dominator front caliper seems to work so far.
Another tip if you are having trouble cleaning the old detritus out of a caliper is to use a blowtorch to heat the inside of the caliper with all the pistons and seals out, if you do this the old crap dries out and turns to dust which is easily removed.
Good tip that.
Nothing wrong with using brake fluid as lube - but it'll get wipe off on the 'outside' of the seal, and any residue which remains.......is hygroscopic........(absorbs water), so you'll have a 'dry' piston not much later.
Using lube's leaves some protection against water/moisture corrosion.
All my own theory, mind - I could be mad. Ode To The Motorist
“And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road”
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tutorials, and this one rocks. Nice one! 
