I am seeking advice on how to install the piston and rubber boot on a Series 2 three piston front brake caliper. There has to be some secret to how it is done. Does one first install the boot onto the caliper inserting the rubber lip into the caliper groove and then insert the piston through the boot? Or does one install the piston and then fit the boot somehow inserting the rubber lip into the caliper groove. I have tried both and neither worked. Incidentally, is it done without splitting the caliper in half, and if so how?
Submitted by cleavefamily@c… on Fri, 12/19/2003 - 00:03
Do NOT under any circumstance separate the calipers. I rebuit my calipers years ago when I knew almost nothing and I can't remember the details but I recollect it was a simple procedure and things only went back together one way and I had very little difficulty. I found that a tappered wooden wedge aided disaassembly, I used compressed air to get the pistons out and the tappered wedge let me control the movement so that all the pistons came out evenly until I could remove them with my fingers. That was the hard part until I thought of the wedge. I assume you have the calipers off the car and on a workbench. Cleanliness is most critical - have plenty of clean rags and clean brake fluid ready to lubricate the parts when reassembling them. I think you're supposed to place the "O" ring in the caliper then fit the piston and press it in. A peice of wood run through the caliper helps you press the pistons into place EVENLY by pressing down on each side - the wood centered over the piston. Do not drive the piston's groove all the way in - it should project so that the dust seal can slip around it. The pads help retain the whole thing when offerred up into final position. Don't forget to use some anti squeal lube on the pads and have the rotors turned or replaced. If your having trouble somthing is really wrong. Do the replacement parts look the same as the originals? A good parts house should be able to help - most calipers from that era were basically the same.
Good luck.
Stew Cleave
JOCO Chief Judge
'69 E-Type 2+2 and other LBC's