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Caliper - Rear 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 brake caliper, clean and inspect it. (Refer to CLEANING  and INSPECTION )
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 a practice.
CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion.
  1. Drain brake fluid from caliper.
    Fig 1: Rear Caliper In Vise
    GC0014358Courtesy of DAIMLERCHRYSLER CORP.
  2. Mount caliper in a vise equipped with protective jaws.
  3. Place a wooden block (2) (padded with approximately one-inch thickness of shop towels) in front of caliper (1) piston as shown in Fig 1. 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. This will cushion and protect caliper piston during removal.
    WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to remove piston. Do not use high pressure.
  4. Apply low pressure compressed air to caliper fluid inlet in short spurts  to ease piston out of bore.
  5. Remove piston from caliper (1).
    Fig 2: Rear Caliper Dust Boot Removal
    GC0014359Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: When working on disc brake caliper, always use care and suitable tools to avoid damaging the aluminum housing.
  6. Using a suitable tool (1), carefully remove dust boot (2) and discard it.
    Fig 3: Rear Caliper Piston Seal Removal
    GC0014360Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch bore or leave burrs on seal groove edges.
  7. Using a soft tool such as a plastic trim stick (2), work piston seal (1) out of its groove in caliper piston bore. Discard used seal.
    Fig 4: Rear Caliper Bleeder Screw
    GC0014361Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove caliper bleeder screw (1) from caliper housing (2).
  9. Clean piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth.
  10. 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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