Replacing Front Brake Caliper Dust and Piston Seal

[Action Jackson]

When changing the brake pads, some might notice the following:

http://www.toprotege.com/forums/attachment.php?attachmentid=5870&d=1151623986

A ripped piston dust seal.

This how to will allow you to replace this.

What You'll Need
- Socket Set
- Wrenches
- Allen Keys
- A OEM Front Caliper Seal Kit # GAYR 33 26Z [I'd suggest getting 2 of these in case you screw up like I did]
- Jack and stands
- New Brake Fluid
- Disc Brake Spreader Tool [works better than a C Clamp]
- Brake Parts Cleaner Fluid/Spray
- Good Lighting
- Good Ventilation
- Bin to Catch Used Brake Fluid
- Several Clean Lintless rags
- Someone to help bleed the brakes (and maybe the clutch)
- Gloves If You Wish
- A Small Thin Tool to Remove Piston Seal like a Dull Putty Scraper
- Air Compressor suggested
- Brake Slider Lube of Your Choice
- Eye and Ear Protection If You Wish.

[Action Jackson]

Some of the tools and equipment:
http://www.toprotege.com/forums/attachment.php?attachmentid=5871&d=1151623996
The Brake Spreader Tool.

http://www.toprotege.com/forums/attachment.php?attachmentid=5872&d=1151624002
and the seal kit. Each kit will be enough to do both front calipers.

[Action Jackson]

1.
- Spray everything down with Brake Cleaner. Wipe if necessary.
- Have something ready to catch the brake fluid.
- Remove the Brake Lines from the back of the caliper :
http://www.toprotege.com/forums/attachment.php?attachmentid=5873&d=1151624010

[Action Jackson]

2.
- It's just like changing the brake pads, so I'll skip some of that explanation, but in a nutshell it takes an Allen Key to do that part.
- You'll need to slide up the caliper:
http://www.toprotege.com/forums/attachment.php?attachmentid=5874&d=1151624016

[Action Jackson]

3.
- This part is like changing the rotors. Remove the caliper off it's slider:
http://www.toprotege.com/forums/attachment.php?attachmentid=5875&d=1151624059

[Action Jackson]

4.
- The air compressor will come in handy. You might recognize this as an air nozzle to blow off debris:
http://www.toprotege.com/forums/attachment.php?attachmentid=5876&d=1151624064

- You'll need to remove off the tapered nozzle:
http://www.toprotege.com/forums/attachment.php?attachmentid=5877&d=1151624072

[Action Jackson]

5.
- It's a good idea to clean the caliper that you removed with Brake Cleaner.
http://www.toprotege.com/forums/attachment.php?attachmentid=5878&d=1151624077

- Don't use pieces of wood shown here. Instead use a whole bunch of rags b/c the piston will blow out with a bang.
http://www.toprotege.com/forums/attachment.php?attachmentid=5879&d=1151624083

[Action Jackson]

6.
- Gently insert the air nozzle
- using short bursts, gently blow air into the hole
- Be careful as it can blow out with a real bang!
http://www.toprotege.com/forums/attachment.php?attachmentid=5885&d=1151624203

[Action Jackson]

7.
- don't know if the piston seal was already damaged, or damaged from having the piston popped out with air, but here it is:

http://www.toprotege.com/forums/attachment.php?attachmentid=5886&d=1151624212

- When it's removed here's another shot:
http://www.toprotege.com/forums/attachment.php?attachmentid=5887&d=1151624217

[Action Jackson]

8.
- 2 shots of the caliper piston:

http://www.toprotege.com/forums/attachment.php?attachmentid=5888&d=1151624223
http://www.toprotege.com/forums/attachment.php?attachmentid=5889&d=1151624228

[Action Jackson]

9
- After cleaning out the caliper, insert the new seal. I used some fresh brake fluid to lube the seals:
http://www.toprotege.com/forums/attachment.php?attachmentid=5890&d=1151624260

- and clean off the piston as well. Lube the piston with fresh brake fluid:

http://www.toprotege.com/forums/attachment.php?attachmentid=5891&d=1151624266

[Action Jackson]

10.
- Lube up the new dust seal with fresh brake fluid. This photo shows the supplied grease, I don't use it anymore, just fresh brake fluid.
http://www.toprotege.com/forums/attachment.php?attachmentid=5892&d=1151624278

- slide the dust seal near the end (but not off) the piston:
http://www.toprotege.com/forums/attachment.php?attachmentid=5893&d=1151624284

[Action Jackson]

11.
- if you're wondering, installing the seal this way makes it extremely difficult to install so I don't recommend it.
http://www.toprotege.com/forums/attachment.php?attachmentid=5894&d=1151624290

[Action Jackson]

12.
- carefully insert the piston with the seal near it's bottom into the caliper:

http://www.toprotege.com/forums/attachment.php?attachmentid=5895&d=1151624326

- gently use your hands to push the piston into the caliper, but there came a point where I had to use the brake spreader to help out:
http://www.toprotege.com/forums/attachment.php?attachmentid=5896&d=1151624332

[Action Jackson]

13.
- I had to gently offset the spreader and manually help push in the piston:
http://www.toprotege.com/forums/attachment.php?attachmentid=5897&d=1151624337

- and I finished off by compressing the rest of the piston in with a used brake pad.
http://www.toprotege.com/forums/attachment.php?attachmentid=5898&d=1151624343

[Action Jackson]

14.

- All I can suggest is to not crush your new dust seal and reinstall everything carefully.
- if you want to change the rest of the rubber bits go ahead. Use proper brake lube and clean the sliders off first.
- Don't forget to bleed the brakes!
- Enjoy saving $$$
- Many thanks to Kevin Goddin and James Weaning at Dave Wood Mazda.

http://www.toprotege.com/forums/attachment.php?attachmentid=5899&d=1151624352

[ESsedan01]

Jackson, nice how to write up!

Can you tell me how much the new seal kit costs?

I was considering doing this as well.

[CrazyCaker]

Awesome, I have one that needs replacing. How much for the seal kit?

[Action Jackson]

Sorry guys. I didn't realize that there was a response within this thread.

The seal kit costs $47.57 plus tax. 1 kit is enough to do both front calipers.

So that comes out to $47.57 + 14% tax - 17% club discount = $46.35 approximately.

[Action Jackson]

Diagram of OEM brake caliper system.

http://www.toprotege.com/forums/attachment.php?attachmentid=6026&d=1153971525

[viper_707]

so the one kit has two sets of seals for both calipers? also is it the same kit for the front and the rear?

[ESsedan01]

so the one kit has two sets of seals for both calipers? also is it the same kit for the front and the rear?

No the front and back are different size caliper pistons so I would think the seal kits are different.

[Action Jackson]

No the front and back are different size caliper pistons so I would think the seal kits are different.

That's correct.

[viper_707]

but one kits has double seals so both calipers can be done complete

[DarKrID3r]

will this help my brakes to brake more smoother? one of my caliper was freakin hard to squeeze when i painted my calipers.... it was just ***ked up and i think its not breaking well because of that.

what should i do and WHAT SHOULD I BUY?

[TheMAN]

the dust seal *should* be installed AFTER the piston is back in to prevent damage... and of course to make piston removal easier, the dust seal should be removed first

[DarKrID3r]

will this help my brakes to brake more smoother? one of my caliper was freakin hard to squeeze when i painted my calipers.... it was just ***ked up and i think its not breaking well because of that.

what should i do and WHAT SHOULD I BUY?

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