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Caliper - Front Twin Piston Disc Brake: Disassembly

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Before disassembling the brake caliper, clean and inspect it. (Refer to CLEANING and INSPECTION procedures)
WARNING: Under no condition should high pressure air ever be used to remove a piston from a caliper bore. Personal injury could result from such practice.
  1. Drain brake fluid from caliper.
    Fig 1: C-Clamping Wood Over Piston
    GC0014368Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Do not use excessive force when clamping caliper (2) in vise. Caliper housing is made of aluminum. Excessive vise pressure will cause bore distortion.
  2. Mount caliper (2) in vise equipped with protective jaws.
  3. C-clamp (1) a block of wood (3) over one piston.
    Fig 2: Padded Block In Front of Piston Number 2
    GC0014369Courtesy of DAIMLERCHRYSLER CORP.
  4. Take another block of wood and pad it with one-inch thickness of shop towels. Padded block should be sized to allow piston to push out of bore far enough to be removed by hand after being loosened by air pressure, yet large enough to keep piston from coming completely out.
  5. Place the padded block of wood (1) in outboard shoe side of caliper (2) in front of exposed piston (3). This will cushion and protect caliper piston during removal.
    WARNING: Do not place face or hands near caliper and piston if using compressed air to remove piston. Do not use high pressure.
    WARNING: Never attempt to catch piston as it leaves bore. This could result in personal injury.
    CAUTION: Do not blow piston out of bore with sustained air pressure. This could result in a cracked piston. Use only short spurts of air.
  6. Apply short spurts of low pressure air  with a rubber tipped blow gun through caliper brake hose port. Use only enough air pressure to ease piston out of bore.
  7. Remove piston from caliper (2).
  8. Remove C-clamp and block of wood.
    Fig 3: C-Clamp Over Piston Number 2 Boot
    GC0014370Courtesy of DAIMLERCHRYSLER CORP.
  9. C-clamp (1) the block of wood (3) over dust boot of first piston removed. This will seal empty piston bore.
    Fig 4: Padded Block In Front of Piston 1
    GC0014371Courtesy of DAIMLERCHRYSLER CORP.
  10. Move padded piece of wood (1) in front of piston (2) yet to be removed.
  11. Remove second piston using same procedure with short spurts of low pressure air  .
  12. Remove C-clamp and block of wood from caliper.
    Fig 5: Removing Dust Boots
    GC0014372Courtesy of DAIMLERCHRYSLER CORP.
  13. Remove piston dust boots (1) (over each bore) with an appropriate pry tool (2). Use care not to damage aluminum housing. 
    Fig 6: Removing Piston Seals
    GC0014373Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Use an appropriate tool (1) to remove piston seals (2) to avoid scratching piston bore. Do not use a screwdriver or other metal tool to remove seals.
  14. Using a soft tool such as a plastic trim stick (1), remove piston seals (2) from caliper bores.
    Fig 7: Twin Piston Caliper Bleeder Screw
    GC0014374Courtesy of DAIMLERCHRYSLER CORP.
  15. Remove caliper bleeder screw (2) from caliper housing (1).
  16. Clean piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth.
  17. Inspect both piston and bore for scoring or pitting.
NOTE: It is not recommended to hone caliper bore. The anodized coating would be compromised.
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