Piston for front brake caliper, removing and installing

Special tools, testers and auxiliary items required

Fig 1: Identifying Trim Removal Wedge 3409

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Wedge 3409

Fig 2: Piston Resetting Tool T10145

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Piston resetting tool T10145
Lithium grease G 052 150 A2

Removing

Fig 3: Forcing Pistons Out Individually Of Brake Caliper Housing Using Compressed Air

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Force pistons out individually of brake caliper housing using compressed air.

Only one piston can be forced out at a time. When doing this, hold the opposing piston in the caliper using the piston resetting tool - a -. Block = other pistons using a suitable item, such as a block of wood - b -. When using piston resetting tool, place an additional piece of wood - c - between tool and piston to prevent damage to the piston when it is pushed out.

Fig 4: Removing Seal Using Trim Removal Wedge 3409

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Remove seal using Trim Removal Wedge 3409.

When removing make sure that the surface of the cylinder is not damaged.

Installing

The surface of the piston and seal must only be cleaned with methylated spirits and then dried.
Thinly coat piston and seal with lithium grease G 052 150 A2 before inserting.

Fig 5: Inserting Oil Seal In Brake Caliper Housing

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Insert oil seal in brake caliper housing.

Fig 6: Placing Protective Seal On Piston

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Place protective seal on piston.

Fig 7: Using Equal Pressure To Push Piston Into Brake Caliper Housing

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Using equal pressure, push piston into brake caliper housing.

The protective seal should locate securely in the piston groove. If not, use piston resetting tool to push piston in further.