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Old 09-19-2008, 08:43 AM   #1
N8WRX
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Default DIY: Brembo Caliper Disassembly

So I was looking for a DIY the other day and I couldnt find one. I posted up a thread and got some good feedback, enough so that I knew what I was doing. I figured id take some pics and do a small write up for anyone looking to take these apart for new seals or paint. My personal reasoning for doing this is that I am sending them out to be powder coated black and the company wanted me to take them apart prior to them being sent. Well here we go...


I started with the calipers off the car already, Its fairly simple to take them off the car so this how to will begin with calipers taken off.

STEP 1: If you have not yet removed calipers from the car remove them, I cleaned mine prior to starting. You will need to disconnect the brake lines and unbolt them from the hub. Also remove the pads, to remove the pads there are 2 pull pin clips thru a set of long pins. The pins hold the pad and metal bracket in place. Remove the 2 pull pins and slide out the 2 longer pins and everything will fall out. Keep in mind there are small plates on the back sides of the brake pads where the pistons hit the pad, these can be easily lost and are marked with arrows for direction.



STEP 2: You then need to split the calipers apart, to do this I used a impact wrench but if you have some good strength it is possible to break the bolts. Pretty sure the Bolts on the front are a 13mm and the rears use a allen wrench style bolt which i believe is a size 6. NOTE: I could be wrong about sizes on these


STEP 3: You will want to pop the pistons out. In order to do this I used, for the rear a inch by 5 inch block of wood, for the front you will need a little thicker of a block. Place the block where the rotor would sit so that the piston doesn't shoot out and kill someone. (trust me these things will FLY) After doing this i made sure my bolts were very lightly tightened into place, I did this because if you leave the gap the pistons will put force in the way of least resistance which basically means its going to shoot the caliper apart and split it which could cause some pain . Next is to use a air compressor and shoot air in the inlet for the brake fluid, when you do this the pistons should extend out and hit the block of wood.



STEP 4: After splitting the calipers and popping the pistons I removed the rubber seal between the 2 pieces as it is small and could very easily be lost. NOTE: dont remove the o-ring prior to step 3 or step 3 is pretty much impossible.



STEP 5: Remove the boot that is around the calipers piston. To do so you will see a small small hole between the boot and the caliper itself. I used a very small allen wrench, stick the wrench into the small hole and just pry out the boot it should just pop right out.




STEP 6: After the boot is out and the piston is extended all that is left is to remove the piston. To do this you will need a screw driver and something soft like a towel. I wrapped the end of the screw driver in the towel and used the small lip on the piston to pry it out. Once the piston passes the seal on the inside of the piston hole it will pop and you can remove the piston by hand. !!!!!!WARNING!!!!!!!: DO NOT SCRATCH/DAMAGE/CHIP THE SIDE WALL OF THE PISTON THIS WILL RESULT IN A BROKEN SEAL AND A USELESS PISTON.



STEP 7: Send out your calipers for powder coating!



BREMBO REBUILD PART NUMBER:
Front: 26297fe010
Rear: 26697fe000

bleeder screws: 26238fe000
bleeder screw caps: 26241fe000
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Last edited by N8WRX; 10-28-2008 at 01:09 PM.
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Old 09-19-2008, 10:45 AM   #2
Badler
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Nice write-up! Not hard at all. Did you end up getting the new seals?
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Old 09-19-2008, 11:55 AM   #3
N8WRX
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I have not got the seals yet but i think im going to do it. I have a little while till they get back to me to reassemble anyway

Last edited by N8WRX; 10-28-2008 at 12:19 PM.
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Old 09-19-2008, 12:03 PM   #4
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Who's powder coating them? I'm not much for the gold color myself.
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Old 09-19-2008, 12:05 PM   #5
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cant tell you that, its a secret lol I can however tell you they will be black with a blue BREMBO
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Old 09-19-2008, 12:34 PM   #6
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wear eye protection!

i used to rebuild sportbike calipers...those pistons things LOVE to shoot all over the place. it's easy! same exact guidelines as cars but only smaller...and if you screw up...your FACKED

do replace all the seals even if you don't feel you need to! you've come this far already right? it's only a bit more $ and really no extra work!

also, probabably test it for leaks when you get it together. better finding leaks at this point than on the car. but unless you score something, you shouldn't have any issues.
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Old 09-19-2008, 01:59 PM   #7
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When i get my seals i might do a DIY on replacing those and just pick up where i left off.

Last edited by N8WRX; 09-25-2008 at 08:06 AM.
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Old 09-19-2008, 02:29 PM   #8
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do you have a mity vac as well for bleeding? it would be an awesome DIY since i see so many people having issues with bleeding.

i just did brake service on my bike for sale sunday...mity vac is great for bleeding but mang...my wrists are still so sore from the massive pumping i had to do for it!
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Old 09-21-2008, 02:22 PM   #9
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Make sure you dont damage the rubber O ring that goes between the caliper halfs those things have yet to be sourced by anyone!
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Old 09-25-2008, 08:07 AM   #10
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Yes, i made sure to baggie that one along with all my other items in labeled sandwich baggies
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Old 10-19-2008, 08:56 PM   #11
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Quote:
Originally Posted by Token-Negro View Post
Make sure you dont damage the rubber O ring that goes between the caliper halfs those things have yet to be sourced by anyone!
+1 I just got the so called "brembo seal kit" from the dealer and there was no tiny o rings in there. They look to be in good shape so I will just reuse them.
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Old 10-22-2008, 01:00 PM   #12
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Update 10/22/08 i got the calipers back from paint and put on the brembo, they came out GREAT!
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Old 10-22-2008, 02:13 PM   #13
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Looks good!
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Old 10-23-2008, 02:28 AM   #14
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looking good!!! where did you source the decals? are they high temp?
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Old 10-26-2008, 05:33 PM   #15
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Quote:
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looking good!!! where did you source the decals? are they high temp?
http://xenonmods.com/
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Old 10-28-2008, 12:25 PM   #16
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updated with part numbers for front and rear rebuild kits and quick bleeder screws, #'s in first post at the bottom
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Old 11-10-2008, 02:56 PM   #17
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do you know what they used to strip them?
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Old 01-07-2009, 04:20 PM   #18
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where do you get the rebuild kits from
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Old 01-08-2009, 01:03 PM   #19
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Quote:
Originally Posted by bugeyesubie View Post
where do you get the rebuild kits from
x2..

and how are the calipers stripped from the gold color before powdercoat?

can they be sandblasted?
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Old 01-09-2009, 12:10 AM   #20
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Hi All,

Everything I have seen suggest AGAINST splitting the calipers...

Ray
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Old 01-09-2009, 12:14 AM   #21
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Hi All,

Everything I have seen suggest AGAINST splitting the calipers...

Ray
Care no explain Ray?
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Old 01-09-2009, 12:32 AM   #22
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The bolts are use once, throw away stretch bolts, if ANYTHING happens to the machined surfaces you have a problem - leaks, cannot source MOST parts - I have a set that need pistons which I cannot get, so they are junk...

Unfortunately, I don't have time to find the 'official' word, so this is in the IMHO category...

Ray
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Old 01-09-2009, 01:19 AM   #23
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Even if you do split them for whatever reason, doing so would be a better idea with the caliper still bolted to the car. Well don't actually split them on the car but just crack the bolts when on the car.
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Old 01-09-2009, 11:25 AM   #24
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Quote:
Originally Posted by bugeyesubie View Post
where do you get the rebuild kits from
you can get them from any dealer. sgp on here can get them to you also.

when i rebuilt mine i also split them. you just need to be very careful about that oring and the machined surfaces.

I cant comment on the bolt stretching as i am not sure if these are stretch to yield or what.
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Old 01-30-2009, 08:46 PM   #25
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I would prefer to use a Brembo stencil for refinishing. This way you can paint it on and not worry about it ever coming off. Link to stencils below:

http://eagleday.stores.yahoo.net/factorydecals.html


I recently rebuilt my Brembo calipers.....I split them thinking I would be able to do a more complete job. I had a local company dip the calipers to get the old paint off. There was a black anodized coating under the gold paint which apparently is used to protect the caliper from corrosion.

Things I would do differently next time:

I powder coated the calipers before reassembling. I thought by having the mating surfaces taped that I would be okay. When I put the calipers back together and torqued them down the powder coating cracked along the seam. Next time I will reassemble first then powder coat. The little o-ring should be able to take the heat of powder coating

I stripped out a hex bolt trying to take it off the caliper. I didn't try any others after that. Took the calipers to a machine shop and they removed them for me.
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