FRONT CALIPER REBUILD
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I'll try to go about explaining the caliper rebuilds. However, this was
during my suspension rebuild, so some of the pics may look weird.
Tools needed: Various sockets and spanners Screwdriver Rebuild kit
~$15 Footpump (to remove caliper piston) SST #09756-00010 (for rears, necessary
for full rebuild) - NOT NECESSARY, USE ADJUSTABLE PLIERS Denatured alcohol or brake fluid (to clean parts)
Front Removal and Assembly
Here's the front rebuild kit, about $15 from local auto parts store.
1) Loosen wheel nuts, raise and support front of vehicle. Remove wheel nuts
and wheel.
2) Drain the brake fluid pressure from the bleed valve on the caliper. Place
a hose over the valve and use an 8mm spanner to loosen the valve.
3) Remove the two 12mm bolts that hold the caliper to it's mounting bracket.
4) Remove the 14mm banjo bolt holding the brake line to the caliper. Expect
some brake fluid to leak through.
5) Here's some pics of the caliper removed.
6) Push the slider out one side of the caliper. I just used a pair of pliers
as shown below to do this.
7) It should pop loose, then you can pull it the rest of the way out
8) Remove the 2 rubber dust boots.
9) Inside the caliper, you will see a collar. Remove this.
10) Do the same for the other sliders, and here's the parts you will have
removed.
11) Use a small screwdriver to pry out the piston set ring.
12) Pull out the piston boot.
13) Remove the piston from the cylinder with foot pump connected to the banjo
bolt hole. Tighten the bleeder valve and make sure to place a block of wood or a
rag inside the caliper, so that when the piston pops out it is not damaged. And
believe me it will POP.
14) Pry out the piston o-ring with a small screwdriver. Be careful not to
score the cylinder walls.
15) Just a pic of the cleaned up calipers after under a brass cleaning wheel.
16) Clean the sliders and collars in denatured alcohol or clean brake fluid.
17) Also, clean the inside of the cylinder and the piston with denatured
alcohol or brake fluid.
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