DIY: How to rebuild your front calipers

Do It Yourself. Feeling game try some of the mods outlined in here. Some of these can be peformed by novices others require a substantial amount of knowledge before attempting them

If you are not sure about something ASK

Moderators: IMC, Club Staff

User avatar
Vectose
Forum Moderator
Posts: 3947
jedwabna poszewka promocja
Joined: Sun Nov 28, 2010 8:45 pm
Location: Newcastle

DIY: How to rebuild your front calipers

Post by Vectose »

I rebuilt a set of calipers today and thought I would post up a DIY for anyone else that wants to do it.

Disclaimer: Doing anything to your brakes can be dangerous if it is not done correctly. If you are not 100% confident in doing this, don't do it. I will not be held responsible for brakes failing.


First thing you will have to do is remove the caliper from the car or use a second set. Follow the beginning of this guide to remove the calipers from your car.

One thing that isn't mentioned in the guide above is to remove the brake line from the caliper, to do this use a 14mm spanner or socket.

Image

What you'll need
Air compressor and blow gun
Block of wood (I used the handle of my rubber mallet)
Rags
Brake fluid
Brake Cleaner
Rebuild kit (MB857840) You will need two of these, one for each caliper
Flat screwdriver
Something plastic or wooden to remove the seal like a zip tie or skewer
2000 grit sandpaper

Step 1. Remove the old retaining ring holding the dust boot in with a flat screwdriver

Image

Image

Step 2. Place a block of wood and some rags in front of the pistons and using your blow gun, blow some air in through the brake line hole.

Image

Image

This will force the pistons out and the rags will soften the blow, you need to make sure one doesn't pop out before the other as it will be impossible to remove the other one without re-inserting the one that popped out.

Image

Be sure to keep your fingers clear of the pistons. (You can also use the old brake pads instead of a block of wood)

Step 3. Once the pistons have been blown out you should be able to remove them by hand. Don't try to use pliers or you may damage the surface. If you are having a bit of trouble removing them, give them a little wiggle and twist.

Image

Step 4. Spray some brake cleaner on the piston and wipe it with a rag to clean off any solidified brake fluid/contaminants. If there is minor pitting on it, you can use some 2000 grit sandpaper to remove it.

Image

Image

Image

Image

If there is major pitting on the piston then you will need to get a replacement.

Step 5. Using a skewer or zip tie, remove the old square seal from the caliper. The reason you don't use a screwdriver or anything metal is because you don't want to scratch the inside of the caliper.

Image

Step 6. Give the inside of the caliper a good clean with some brake cleaner.

Remove any corrosion in the cylinder bore using some 2000 grit sand paper. You won't be able to get it completely clean but as long as it feels smooth it should be good.

Give it another spray with brake cleaner and make sure the seal groove is completely clean.

Step 7. Remove the contents from the rebuild kit. The rebuild kit includes (from top to bottom on the photo)

Square seals, dust boots, dust boot retaining rings, slide pin dust boots and assembly lube. Also, not pictured it includes the little rubber bush for the slide pin.

Image

Image

Step 8. You may want to put on some nitrile gloves for this.

Apply some brake fluid to the cylinder bore and the square seal. I like to pour some brake fluid in the cap and spin the seal around in it.

Image

Image

You should also not stick your fingers into the brake fluid bottle if you plan on using it to top up your cars fluid as you may contaminate it.

Step 9. Install the seal into the caliper, making sure there are no twists in it.

Image

Step 10. Apply some brake fluid to the pistons and stretch the dust boot over.

Image

Repeat the above steps with the second piston.

Image

Step 11. Push the pistons into the caliper. It does require some force and if you can't do it by hand use a G-clamp or piston compressor tool.

Image

Step 12. Using a skewer or dull flat head screwdriver, push the edge of the dust boot into the groove on the caliper.

Image

Image

The dust boot has a lip that sits flush with the groove and you need to make sure it is all the way in. I took a photo showing what it looks like when it isn't seated properly.

Image

Step 13. Insert the new retaining ring, this may be a little tricky but I found the best way is to insert one side and then kind of twist and push it.

Image

Image

Repeat the above steps for the second piston.

Image

Step 14. We are almost done. We just have to push the pistons out with the blow gun one more time to make sure the boots and rings are seated properly. Add a bit more packing in front of the pistons this time as we don't want them popping out all the way.

Image

The other dust boots in the kit are for the slider pins and they go on the caliper bracket.

Image

Image

The tiny bush, goes on one of the slider pins. Just slide it off, wipe off any old grease, apply new grease that was supplied with the rebuild kit and slide the new bush on.

Image
Last edited by Vectose on Sun Dec 14, 2014 11:39 am, edited 2 times in total.
Bennoz wrote:
Technikhaus wrote:What is in said Bens big penis by the way?
A whoooole lot 'o jism 8)
User avatar
SchumieFan
Oldtimer
Posts: 5875
Joined: Thu Aug 05, 2004 5:00 pm
Location: GPS signal lost
Contact:

Re: DIY: How to rebuild your front calipers

Post by SchumieFan »

nice one... :thumleft:







no you cant have my brakes
Image
User avatar
kiz
SA Coordinator
Posts: 2178
Joined: Wed Nov 09, 2011 10:09 pm
Location: Adelaide, South Australia

Re: DIY: How to rebuild your front calipers

Post by kiz »

Nice DIY, will come in handy if get stuck when I do mine when i'm next free
There are two types of people on forums; those that give helpful advice, and the others

1998 Mitsubishi FTO GPVR AERO ;)
User avatar
Vectose
Forum Moderator
Posts: 3947
Joined: Sun Nov 28, 2010 8:45 pm
Location: Newcastle

Re: DIY: How to rebuild your front calipers

Post by Vectose »

:lol: I didn't want your brakes. I have 3 sets of calipers. Was just asking if you wanted me to rebuild them for you.
Bennoz wrote:
Technikhaus wrote:What is in said Bens big penis by the way?
A whoooole lot 'o jism 8)
User avatar
SchumieFan
Oldtimer
Posts: 5875
Joined: Thu Aug 05, 2004 5:00 pm
Location: GPS signal lost
Contact:

Re: DIY: How to rebuild your front calipers

Post by SchumieFan »

nah... but ill recommend your services when i sell them :D
Image
User avatar
Astron_Boy
Trolling Gen Y
Posts: 8400
Joined: Sun May 27, 2007 5:00 pm
Location: Wine Country NSW
Contact:

Re: DIY: How to rebuild your front calipers

Post by Astron_Boy »

Sweet DIY.
Image
User avatar
Sahin
HULK
Posts: 5518
Joined: Wed Oct 05, 2011 10:38 pm
Location: Up to me nuts in boys guts

Re: DIY: How to rebuild your front calipers

Post by Sahin »

Nice one c**t
silverGPX
9.5"
Posts: 6793
Joined: Tue Oct 13, 2009 5:00 pm

Re: DIY: How to rebuild your front calipers

Post by silverGPX »

f**k yeah, keen sahin?
silverGPX
9.5"
Posts: 6793
Joined: Tue Oct 13, 2009 5:00 pm

Re: DIY: How to rebuild your front calipers

Post by silverGPX »

If i sent these to you vectose how much would you charge to do it lol
User avatar
Astron_Boy
Trolling Gen Y
Posts: 8400
Joined: Sun May 27, 2007 5:00 pm
Location: Wine Country NSW
Contact:

Re: DIY: How to rebuild your front calipers

Post by Astron_Boy »

silverGPX wrote:If i sent these to you vectose how much would you charge to do it lol
Should do an exchange program Vectose!
Image
silverGPX
9.5"
Posts: 6793
Joined: Tue Oct 13, 2009 5:00 pm

Re: DIY: How to rebuild your front calipers

Post by silverGPX »

I'd do it myself but i dont have an air compressor and im not going to buy another tool :lol:
User avatar
Sahin
HULK
Posts: 5518
Joined: Wed Oct 05, 2011 10:38 pm
Location: Up to me nuts in boys guts

Re: DIY: How to rebuild your front calipers

Post by Sahin »

I know who has an air compressor lol
User avatar
Vectose
Forum Moderator
Posts: 3947
Joined: Sun Nov 28, 2010 8:45 pm
Location: Newcastle

Re: DIY: How to rebuild your front calipers

Post by Vectose »

silverGPX wrote:If i sent these to you vectose how much would you charge to do it lol
Not sure what to charge. :lol:

Might not be worth it after shipping costs.
Bennoz wrote:
Technikhaus wrote:What is in said Bens big penis by the way?
A whoooole lot 'o jism 8)
User avatar
Bennoz
National President
Posts: 23668
Joined: Fri Jan 21, 2005 6:00 pm
Location: Sydney
Contact:

Re: DIY: How to rebuild your front calipers

Post by Bennoz »

Astron_Boy wrote:
silverGPX wrote:If i sent these to you vectose how much would you charge to do it lol
Should do an exchange program Vectose!
Yeah that works really well, especially when lazy bastards 'forget' to send their used item back... yeah im lookin' at you Sidds! It's your fault the lower engine mount exchange system is busted!
User avatar
Astron_Boy
Trolling Gen Y
Posts: 8400
Joined: Sun May 27, 2007 5:00 pm
Location: Wine Country NSW
Contact:

Re: DIY: How to rebuild your front calipers

Post by Astron_Boy »

Bennoz wrote:
Astron_Boy wrote:
silverGPX wrote:If i sent these to you vectose how much would you charge to do it lol
Should do an exchange program Vectose!
Yeah that works really well, especially when lazy bastards 'forget' to send their used item back... yeah im lookin' at you Sidds! It's your fault the lower engine mount exchange system is busted!
f**ken lol!

I guess the trust factor gets stretched thin sometimes.

Meanwhile Rob, when I rebuild the engine, might swap you ours for a set of rebuilts with some cash your way, that way I know the car will be 100% solid for quite a while.
Image
silverGPX
9.5"
Posts: 6793
Joined: Tue Oct 13, 2009 5:00 pm

Re: DIY: How to rebuild your front calipers

Post by silverGPX »

Vectose wrote:
silverGPX wrote:If i sent these to you vectose how much would you charge to do it lol
Not sure what to charge. :lol:

Might not be worth it after shipping costs.
I get free postage from my end
User avatar
Vectose
Forum Moderator
Posts: 3947
Joined: Sun Nov 28, 2010 8:45 pm
Location: Newcastle

Re: DIY: How to rebuild your front calipers

Post by Vectose »

Does $50 per caliper sound fair?
Bennoz wrote:
Technikhaus wrote:What is in said Bens big penis by the way?
A whoooole lot 'o jism 8)
silverGPX
9.5"
Posts: 6793
Joined: Tue Oct 13, 2009 5:00 pm

Re: DIY: How to rebuild your front calipers

Post by silverGPX »

Vectose wrote:Does $50 per caliper sound fair?
Not really lol
User avatar
Vectose
Forum Moderator
Posts: 3947
Joined: Sun Nov 28, 2010 8:45 pm
Location: Newcastle

Re: DIY: How to rebuild your front calipers

Post by Vectose »

That includes return postage.
Bennoz wrote:
Technikhaus wrote:What is in said Bens big penis by the way?
A whoooole lot 'o jism 8)
User avatar
Bennoz
National President
Posts: 23668
Joined: Fri Jan 21, 2005 6:00 pm
Location: Sydney
Contact:

Re: DIY: How to rebuild your front calipers

Post by Bennoz »

f**k, don't ask him for costings. You'll be eating coal & shitting diamonds.
Post Reply