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Old 06-07-2011, 09:39 AM   #1 (permalink)
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Default How-to guide to rebuild brake calipers

How-to guide for rebuilding your calipers.

Had thes EX calipers around that had stuck pins and pistons so i decided to rebuild them, make a DIY and then sell them. This DIY was actually done a few years ago but i never got around to posting it.

OEM Honda Caliper Rebuild Kit. 1 for each caliper.



Rebuilding the caliper

Here are the parts you'll be using for the caliper piston



Remove the piston by blowing air into the back of the caliper. place a block of wood in front of the piston so as to not dent anything when it shoots out. EDIT: Sorry i do not have a photo of this step and no longer own these calipers to take a filler picture.

Remove the old piston boot ring, the old boot and the old piston seal from the caliper

Clean up the piston, it should come out as clean as this. If it is rusted, pitted or scared consider buying a new set of pistons or buying a rebuilt caliper.



clean out the piston-well thoroughly. Make sure there is no debris or rust on the walls or the seal grooves. Take the packet of red rubber grease(thick viscosity grease) and coat the inside.



coat the piston seal ring with the red rubber grease and install into the groove



coat the piston with the same red rubber grease



coat the piston boot with grease on both sides and in the accordion grooves. install the piston boot onto the piston with the correct orientation.



place the piston into the well, and using a c-clamp and a block of wood, carefully and evenly apply pressure to push the piston back into the caliper.

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Old 06-07-2011, 09:41 AM   #2 (permalink)
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leave about 1/4" between the boot and the caliper, this gives you room to manipulate the outer edge of the boot into the caliper groove



using your fingers and a small flat-head screwdriver, push the outer edge of the piston boot into the groove of the caliper<p>



boot fully installed



now we need to install the retaining ring. start by wedging the back in place then work one side down into the groove then the next side



the ring pretty much disappears into the groove. take your clamp and push the piston completely into the caliper. Using air, push the piston out of the caliper part ways. Then push the pistion back into the caliper. It is important to do this to double checking proper function of the boot

rinse and repeat for the second caliper

Rebuilding the caliper mounting bracket

Remove caliper pins and caliper pin boots. Thoroughly clean the caliper bracket hole(q-tip works well!) You do not want to leave any debris or old grease in there. Apply a little of the orange grease packet (thinner viscosity).



Thoroughly clean the caliper pin. Take the orange grease packet and coat the pin and the new pin boot.



Install the caliper pin boot onto the mounting bracket



Install the pin into the caliper mounting bracket. Make sure the boot slips over the ridge on the pin. This secures the boot to the pin.

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Old 06-07-2011, 09:42 AM   #3 (permalink)
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rinse and repeat for the other pins

Air may be trapped at the tip of the pin so using a table push down hard on the bracket, mine kind of made a farting noise when the air was released.



Congrats you have now rebuilt your calipers!




This along with all of my other DIY articles is available on my website at:
lukekailburn.com: Honda project info and How-to's

Thanks, spread some rep.

-Luke
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Old 06-07-2011, 11:38 AM   #4 (permalink)
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I actually found this on your site a few days ago. This is exactly what i've been needing to get my integ calipers ready to go major rep
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Old 06-07-2011, 01:55 PM   #5 (permalink)
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haha thanks for the rep dude, glad my DIY's have helped you along

-Luke
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Old 06-07-2011, 04:45 PM   #6 (permalink)
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nice write up
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Old 06-07-2011, 06:36 PM   #7 (permalink)
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OUTSTANDING write-up, nice work man.
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Old 06-07-2011, 06:47 PM   #8 (permalink)
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You should get a job at duralast remanufacturing calipers for autozone & advanced auto lmao awesome write up mate.
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Old 06-08-2011, 06:50 AM   #9 (permalink)
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I love me some rep. Thanks everyone

-Luke
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Old 06-08-2011, 07:44 AM   #10 (permalink)
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AWESOME!

HAHA. The texture of them calipers make it seems like they were made out of tinfoil. LOL

Last edited by Sammo115; 06-08-2011 at 07:46 AM.
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Old 06-08-2011, 09:17 AM   #11 (permalink)
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Quote:
Originally Posted by Sammo115 View Post
AWESOME!

HAHA. The texture of them calipers make it seems like they were made out of tinfoil. LOL
when i first read it i thought he wrapped them in something. then i realzied it was the paint lol.

I do have a question, I'm going to admit i didn't have the time and money to get the honda kit, so the napa rep i deal with got me a set that seem pretty good.

however it has no grease. What grease is equivalent to that red rubber stuff that i can actually buy.

i've used the permatex anti-seize lube on the pins with success on my dx calipers (just cleaning and adding fresh lube).
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Old 06-08-2011, 09:31 AM   #12 (permalink)
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yah that's NY winters for ya. Pitted to hell. That was actually por-20 brush on paint. heavy heavy duty shit.

i"m not sure what grease would be the same, maybe any high viscosity grease. check your local parts store, they usually have grease in a round can. i always have one in the garage to grease up parts for different projects (axle ends, shift fork points, etc)

-Luke
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Old 06-08-2011, 04:50 PM   #13 (permalink)
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nice work man rep on good work that i need to do before i swap out my integra brakes in!

where is a good place online to buy the rebuild kits?
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Old 06-08-2011, 04:58 PM   #14 (permalink)
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whoa! Nice work


I thought all you did at home was chill n look at porn all day
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Old 06-08-2011, 05:30 PM   #15 (permalink)
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That's awesome, but I'm lazy so i'll just buy a new set. Lol.
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Old 06-08-2011, 06:38 PM   #16 (permalink)
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Quote:
Originally Posted by Pata View Post
whoa! Nice work


I thought all you did at home was chill n look at porn all day
Quit spying on me perv lol

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Old 06-22-2011, 07:26 PM   #17 (permalink)
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very nice write up! and in good detail aswell
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Old 06-24-2011, 08:54 AM   #18 (permalink)
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Quote:
Originally Posted by stevenarroyo View Post
nice work man rep on good work that i need to do before i swap out my integra brakes in!

where is a good place online to buy the rebuild kits?
majestic

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