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.