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I got my rebuild kit from Bav. Auto. It was pretty easy, I hooked up the hole for the brake line in the caliper to the air compressor and shot out the piston. Aim it at the ground into some towels or something though, that piston could kill somebody. Then you just take off the metal ring holding the boot on and take off the boot. Clean it with some brake fluid, grease the piston with caliper grease, slide it back in and install the new rubber boot and metal ring.
Instead of aiming the piston, place a wood block or old brake pad in the caliper opposite the piston before applying the compressed air. Not too much pressure....50 PSI should be plenty. Place a rag over the whole mess so you don't splatter brake fluid everywhere.
Pull off the dust boot and carefully pry the seal out of the caliper bore.
Clean all the crud out of the piston bore with brake cleaner and let dry. Use ONLY a plastic scraper or fingernail to clean the piston.....a scratch on the piston will destroy the seal. Remove the bleeder screw and clean the passage. Blow it out with compressed air.
Install the new square O-ring seal in the caliper first.
The dust boot is internal on the front calipers. Lube the piston and caliper bore with clean brake fluid and slide the new dust boot over the center of the piston. Don't put the dust boot in the piston groove yet. Slide the boot to the bottom end (flat end) of the piston and insert the boot in the groove in the caliper. Making sure the boot is in the caliper groove all the way around, insert the piston and squeeze it in about halfway. Then pull the outer part of the dust boot out to the piston groove. Now you can press the piston the rest of the way into the caliper. Take care that the boot isn't pinched by the piston. If the boot is properly installed, it will be even all the way around.
On the rear calipers, the boot installs on the outside of the caliper. In that case, go ahead and put the boot on the piston groove before installing it. Press the piston all the way into the caliper, then stretch the boot around the lip on the caliper bore. Install the steel ring to hold the boot on the caliper.
Instead of aiming the piston, place a wood block or old brake pad in the caliper opposite the piston before applying the compressed air. Not too much pressure....50 PSI should be plenty. Place a rag over the whole mess so you don't splatter brake fluid everywhere.
Heh heh. I tried a block of wood first, but the piston broke the wood in half and somehow the piston was became jammed in the caliper. We then maxed out the compressor and it still wouldn't come out. Ended up using a vise to jam it back in, then hooking up the compressor again. :)
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