Brake caliper rebuild
Everything you need can be found at Autozone or Advance Auto Parts.
- DOT3 or DOT4 Brake Fluid
- Permatex brush-top ultra disc brake caliper lube or similar brake lubricant
- Disposable nitrile gloves (don't skimp on this one)
- Brake cleaner
- Plenty of paper towels
- Dentist's-type pick or tiny flat head screwdriver
- Heavy duty large zip ties
Throughout this process, use copious amounts of brake cleaner on every dirty part, then wipe and dry thoroughly.
Remove the two 12mm bolts attaching the caliper to the fork
Gently remove the little brake pad and set it aside
Pull back (compress) the caliper bracket, thus pushing the caliper guide pins in as far as possible.
Shift and tilt the big brake pad so it looks like this
Push one edge of the brake pad over the caliper pin allowing you to easily remove the other side shortly thereafter.
Your caliper should now look like this
Remove the anti-vibration bracket (take note of its orientation)
Remove the ceramic inserts inside the caliper pistons.
Pump the brake lever CAREFULLY and GENTLY and work both pistons with your thumbs so that both pistons slowly pop out TOGETHER. About 150mL +/- 100mL brake fluid will spill out, so be prepared with a catch container below your working area.
Remove all FOUR seals inside the caliper. You will want to clean these carefully and very thoroughly. There is a LOT of dirt and god knows what else inside and behind these seals. This is why you should rebuild your caliper from time to time.
Reassemble all seals. Put one side of the seal in first, then work both ways around the rubber rings until they seat completely.
Pull out the caliper bracket assembly (the rubber boots should be worked off the bracket gently).
One side of the caliper has a rubber boot which cannot be removed. Do not even try or you will destroy it. Clean it in place.
Clean and then lubricate the pins generously.
Spray tons of brake cleaner into the two caliper pin guide holes and make sure you get all of the old crud out.
Insert a bunch of grease with your finger thereafter.
The aftermath should look like so
Lubricate and insert the clean pistons
Push the pistons in with your thumbs until they are flush with the adjacent metal surface
Insert the plastic inserts
Install the anti-vibration pad
Install the big brake pad
The tabs must face the bottom - not the top - of the brake pad.
This is the incorrect (and opposite) way to install the small brake pad. Don't mess this up!
Reinstall the caliper
Bleed the brakes per the FAQ
After bleeding, let the bike rest overnight with zip ties installed like so
Stand on the rear brake while installing these zip ties (it can be tricky)
