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Tip for brake caliper piston removal

Posted: Sun May 23, 2010 6:16 pm
by terryjenner
I tore my brake master cylinder and calipers down today. You need a soft-jawed vise but I only have the aluminum-destroying version of vice jaws. My solution was to clamp a large Jorgensen wood vise into my vise, then clamp the part I was working on into the Jorgensen clamp. It worked great.

In order to keep the piston from flying out as a projectile, I put a block of wood in between the piston top and caliper bracket. As the piston worked its way out a bit, I decreased the dimension of the free space between the piston top and the free world so it wouldn't just shoot out and take me out with it.

If I had my SD card in my camera phone I would have taken a pic, but I can if anyone wants.

Re: Tip for brake caliper piston removal

Posted: Sun May 23, 2010 11:46 pm
by IndianaJohn
I usually just do it on the bike. Unbolt the caliper and let it hang, then just use the master to pump the piston out. Just did this on the 750 a couple of weeks ago. Of course I overhauled the master first.

Re: Tip for brake caliper piston removal

Posted: Mon May 24, 2010 2:10 pm
by Cookie
Some of those are amazingly stuck though. I've had a long sitter just blow the master. I have been lucky enough not to have had to go the grease gun method yet.

Re: Tip for brake caliper piston removal

Posted: Mon May 24, 2010 2:35 pm
by IndianaJohn
Cookie wrote:Some of those are amazingly stuck though. I've had a long sitter just blow the master. I have been lucky enough not to have had to go the grease gun method yet.


Never had to resort to that method either, but I have heard of people doing so. I've used air in the past and decided pumping them out with the master was safer. But if that failed, I might have to go with the grease gun, tho I would dread the clean-up afterward.

Re: Tip for brake caliper piston removal

Posted: Mon May 24, 2010 3:30 pm
by Cookie
Air just made noise on the last couple until I boiled them. The rear took boiling twice. At least I didn't have to deep fat fry them! :-D

Re: Tip for brake caliper piston removal

Posted: Mon May 24, 2010 3:33 pm
by milesoffun
I used the grease method and it was not near as bad to clean up as I thought it would be - 10 minutes and I was good to go.

Re: Tip for brake caliper piston removal

Posted: Mon May 24, 2010 5:34 pm
by morganfrmn
take both apart and use the master cylinder on both at same time... till they get to the end...

Re: Tip for brake caliper piston removal

Posted: Sun Jun 16, 2019 5:07 pm
by DocRoot
I have been lucky enough not to have had to go the grease gun method yet.


Sprout and I just did mine (barnfind 1100) which were amazingly corroded and stuck, and it was no-muss, no-fuss, well, maybe just a little muss:

GreasyCalliper01.jpg

Re: Tip for brake caliper piston removal

Posted: Sun Jun 16, 2019 5:09 pm
by DocRoot
We used the banjo and plugged it with a short piece of copper #14 wire with a bit of the insulation still attached, stuffed up the center and then screwed back in.

You can see the amount of grease the two sides took altogether.

GreasyCalliper02.jpg

Re: Tip for brake caliper piston removal

Posted: Sun Jun 16, 2019 5:14 pm
by DocRoot
The best part of the grease-gun method is that they come apart with no drama. The HUGE pressure of a grease gun is backed up by really low volume so when things let go it is in millimeters, not with a pop or bang... Things ooze, they don't squirt.

Now it's off the the ultrasonic cleaner for some R&R.

Re: Tip for brake caliper piston removal

Posted: Sun Jun 16, 2019 7:49 pm
by pidjones
I've done grease gun, air, and master. I think my favorite is actually the grease gun. A little kerosene bath for it after...

Re: Tip for brake caliper piston removal

Posted: Sun Jun 16, 2019 8:36 pm
by tomk1960
If air doesn't work, this is the method I use that ALWAYS works, every time. And no greasy mess to clean up afterwards.

https://www.youtube.com/watch?v=rHvIA_--BAs

Re: Tip for brake caliper piston removal

Posted: Sun Jun 16, 2019 8:51 pm
by SnoBrdr
IndianaJohn wrote:
Cookie wrote:Some of those are amazingly stuck though. I've had a long sitter just blow the master. I have been lucky enough not to have had to go the grease gun method yet.


Never had to resort to that method either, but I have heard of people doing so. I've used air in the past and decided pumping them out with the master was safer. But if that failed, I might have to go with the grease gun, tho I would dread the clean-up afterward.


I had to do it.

Cleanup wasn't really that bad.

A can of Brake Kleen easily did the trick.

Re: Tip for brake caliper piston removal

Posted: Sun Jun 16, 2019 10:27 pm
by pidjones
I'd much rather deal with the grease than more brake fluid.

Re: Tip for brake caliper piston removal

Posted: Mon Jun 17, 2019 8:27 am
by RAT
You have to clean them anyway ....

Gord(greasey)Jones :lol: