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Old 04-02-2010, 05:07 PM   #1
2slofouru
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Default Oem subaru 4pot/2pot caliper disassembly, pics inside:

I bought a set of oem calipers and wanted to get them powdercoated. Some say to leave them together and the rubber o-rings will be alright while others say disassemble them and re-use the o-rings. I decided to take them apart to powdercoat and just re-use the o-rings. They appeared to be in perfect shape and still springy. Here are the pics of the calipers disassembled, it was a piece of cake. Note I still haven't pulled the pistons because my air tank is empty so I'll just do that at work next week.


Tools needed (calipers off car already):
3/8" ratchet
6 side 14mm shallow socket
6 side 12mm shallow socket
10mm wrench, use the closed end
8mm wrench, use the closed end
One pointed pick to pop the dust boot clips off, easy
I also used a block of wood to smack the wrench a little to break the bolts. You could also just mount the calipers in a vise for more leverage or use an impact.


Here is what most of us will start with, a scraped up caliper. These bad boys are iron and VERY heavy lol:


Rear view showing the four 14mm bolts, one 12mm banjo bolt and one 8mm bleed screw you will remove:


Its a good idea to spray a little of this stuff in the bolt holes to help ease their removal:


After four bolts and one bleeder screw are removed, note the two o-rings sitting in the caliper half on the bottom:


All components disassembled except the pistons because my air tank is empty, the clips around the dust boots pop off with a pick very easily then you just pull the boots off:



Here are the rear 2pots four 14mm bolts, one 12mm banjo bolt and one 10mm bleeder screw later. Their pistons had grease around them but the front calipers had none. These calipers are aluminum and lightweight:


And their components:

Basically built the same way but two less pistons and they are a little different piston size. The o-rings are actually a slightly larger diameter on the 2pots also.
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Last edited by 2slofouru; 03-23-2013 at 12:26 PM.
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Old 04-02-2010, 05:57 PM   #2
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So the two o-rings smaller than a dime, are the only two unobtanium parts?
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Old 04-02-2010, 06:00 PM   #3
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Unless they are some exotic space age rubber I'm sure they would be easy to find. I even have a set of metric o-rings that would probably fit but they are the rounded type. The ones in the caliper have a flat profile, the edges aren't rounded. Basically look like they were cut from a flat sheet of rubber.



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Originally Posted by teiva-boy View Post
So the two o-rings smaller than a dime, are the only two unobtanium parts?
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Old 04-02-2010, 06:51 PM   #4
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You think it's possible to remove the pistons without air? I have a set I was going to paint ala G1 paint kit. But I am getting lazy and just want the powder coaters to blast and coat it, rather than me sand mine down to paint.
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Old 04-06-2010, 07:46 AM   #5
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I ordered a 4pot caliper seal kit from wrxparts.com and it only comes with the front caliper seals, does any other place sell them other than the dealer? I will get them from the dealer if need be but if I can get the oem rear set for less...
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Old 04-06-2010, 07:48 AM   #6
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Quote:
Originally Posted by teiva-boy View Post
You think it's possible to remove the pistons without air? I have a set I was going to paint ala G1 paint kit. But I am getting lazy and just want the powder coaters to blast and coat it, rather than me sand mine down to paint.
If you can find a tool that expands inside the piston, like the rubber engine block plugs that expand when you turn the bolt for example, you can pull them out. I was lucky enough to "pop" mine out with air yesterday. (be careful, they will come out a mach speed)
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Old 04-06-2010, 09:27 PM   #7
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Quote:
Originally Posted by teiva-boy View Post
So the two o-rings smaller than a dime, are the only two unobtanium parts?
Quote:
Originally Posted by 2slofouru View Post
Unless they are some exotic space age rubber I'm sure they would be easy to find. I even have a set of metric o-rings that would probably fit but they are the rounded type. The ones in the caliper have a flat profile, the edges aren't rounded. Basically look like they were cut from a flat sheet of rubber.

maybe somebody could figure out their exact dimestions and post them so somebody could poke around and find something to use as a possible replacement
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Old 04-06-2010, 10:56 PM   #8
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Quote:
Originally Posted by 2slofouru View Post
Unless they are some exotic space age rubber I'm sure they would be easy to find. I even have a set of metric o-rings that would probably fit but they are the rounded type. The ones in the caliper have a flat profile, the edges aren't rounded. Basically look like they were cut from a flat sheet of rubber.
The reason the caliper piston seals are "square" is to help retract the pistons. There is a method in the madness.

The caliper O-rings are not a Subaru service part. (The little ones.) They are probably a standard thing, but measuring O-rings, especially used O-rings is extremely difficult.
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Old 04-06-2010, 11:11 PM   #9
2slofouru
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Sorry, I didn't mean the rings in the caliper bores. I was referring to the ones between the halves. They do have the same design though, not round edges but look like something stamped out of a flat piece of rubber. I don't have a metric micrometer but maybe I could post their approximate dimensions.


Quote:
Originally Posted by Web Foot STi View Post
The reason the caliper piston seals are "square" is to help retract the pistons. There is a method in the madness.

The caliper O-rings are not a Subaru service part. (The little ones.) They are probably a standard thing, but measuring O-rings, especially used O-rings is extremely difficult.
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Old 04-06-2010, 11:16 PM   #10
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Quote:
Originally Posted by 2slofouru View Post
Sorry, I didn't mean the rings in the caliper bores. I was referring to the ones between the halves. They do have the same design though, not round edges but look like something stamped out of a flat piece of rubber. I don't have a metric micrometer but maybe I could post their approximate dimensions.
Oh Shazbat! Sounds proprietary then.
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Old 04-06-2010, 11:16 PM   #11
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Quote:
Originally Posted by 2slofouru View Post
Sorry, I didn't mean the rings in the caliper bores. I was referring to the ones between the halves. They do have the same design though, not round edges but look like something stamped out of a flat piece of rubber. I don't have a metric micrometer but maybe I could post their approximate dimensions.

dont need one....just measure them and post the numbers
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Old 04-18-2010, 04:06 PM   #12
2slofouru
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(sorry, lost this pic)
as far as I could get with cleaning

(sorry, lost this pic)
after powdercoating

I still have to get new rear seals and boots, the kit I bought only came with front parts.

Last edited by 2slofouru; 03-23-2013 at 12:27 PM.
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Old 04-30-2010, 08:00 PM   #13
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how much is the rebuild kit?
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Old 04-30-2010, 10:37 PM   #14
2slofouru
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subaruwrxparts.com has them, I believe it was about $25
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Old 05-24-2010, 08:35 PM   #15
2slofouru
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Got the decals today, and got the rear seal kit (over $50!) a few days back. I sprayed the inner edges with black because the powder coater didn't coat everything. I'll install the pistons and seals later, the engine still needs work so I have some time.

Last edited by 2slofouru; 03-23-2013 at 12:27 PM.
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Old 06-28-2010, 08:46 PM   #16
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For the unobtonium o-ring within the caliper halves

OD 1/2"x 1/16th"
ID about 5/16th"
It's not a rounded/radius o-ring, but rather has squared off edges, like as described by the OP as cut from a tube.

I have no way to measure in mm nor have a caliper, this was done with a cheap old wooden ruler and my eyeball. Accuracy should be taken as +/- 1/32nd...

This website has tons of o-rings for sale, as well as charts to match up what works with brake fluid, and higher temperatures.
http://www.marcorubber.com/

Sizing if I had to guess would be close to a -109 Taken from here:
And this model o-ring makes the most sense Buna-N O-ring

I have not bought anything from them, and I feel my existing o-rings are more than up to the task.

Last edited by teiva-boy; 06-28-2010 at 09:06 PM.
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Old 03-23-2013, 12:28 PM   #17
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Rehosted pics bump
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Old 03-27-2013, 02:07 AM   #18
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i got some measurement of the internal o rings using a caliper. Dont use Buna-N as state above. use EPDM.


http://forums.nasioc.com/forums/show...&postcount=114
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