2nd Generation Specific (1986-1992) 1986-1992 Discussion including performance modifications and technical support sections.

Front brakes - popping pistons

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Old Feb 27, 2004 | 01:58 AM
  #1  
Wankel7's Avatar
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From: Indiana
Thumbs up Front brakes - popping pistons

Well, I got done popping the pistons out of my front calipers. That reall sucked.

When I first put the air pressure to the caliper only one shot out. The same for the other caliper.

So I started using various objects to assit in removing the other pistons.

After the first one popped I put a adjustable wrench infront of the popped one. Then put all my weight on the wrench and aplied the air pressure....then anouther one popped loose.

So I had two poped. Then I was able to fit a small adjustable wrench bettwen the two popped ones. I then slide the two popped ones just a little back into their bore. So it looked like this PwP I had the head of the adj. wrench between the piston.

So with the adjustable wrench between the to pistons that already popped the next air pressure applied popped anouther one loose. One more to go

So I did what I did before (leaving the adjustable wrench in place). I just put anouther wrench infront of the newely popped piston and it the last piston popped.

I suppose if you found some small C clamps you could do this much easier.

I was using about 80psi to do all this. Just make sure you put a rag infront of the piston that you think is gonna go. And it comes flying out of there. So don't use your fingers to hold it!

Also, when I searched I notcied people said they were getting rebuild 4 piston calipers for 36 bucks at the auto parts store. I dunno but down here in southern texas auto zone said 65 for the left side and 87 for the right side.

Hope this helps somebody.

James
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Old Feb 27, 2004 | 03:59 AM
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Gen2's Avatar
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From: bay area
why different prices? procedure is the same.
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Old Feb 27, 2004 | 05:35 AM
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i hear sticking a block of wood between them works well.
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Old Feb 27, 2004 | 08:49 AM
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Wankel7's Avatar
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From: Indiana
the wood would work also.

However, I learned you do not have to put the piston very far into the bore to make a seal. So you slide the two pistons you are blocking all the way into the bore you now have to worry about popping those two back out.

However, if you just barely slide them into the bore you can remove them by hand.

And yeah. Two different prices. I have no idea!

James
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Old Feb 27, 2004 | 09:03 AM
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From: NJ
As stated previously, wood works well because it won't damage/nick the pistons when they "pop" out.
Another way, even though I've never given it a try as I've always used an air compressor, would be to remove the caliper, but leave brake hose attached. Remove the pads, put the wood between the pistons and press on the brake pedal and let the pressure push out the pistons. Would be good for someone that doesn't have an air compressor.
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Old Feb 27, 2004 | 09:13 AM
  #6  
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From: Indiana
I know that wood works well. But was what I was talking about was putting a wrench or anything that would fit between to already popped pistons. These pistons would not go anywhere because of the wood in the way.

And I just used a rag to cussion the flying pistons.



James
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Old Mar 19, 2004 | 09:34 PM
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From: Rutgers
visited the dealer today....the guy told me $30.36 per caliper.....comes with replacement pistons as well as all the rubber parts and the snap rings....please let me know if anywhere else has the parts at a cheaper price
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Old Mar 19, 2004 | 10:59 PM
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den
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From: newcastle/england
i did mine about 8 months ago, trying to get all of the pistons out sucked. then i remembered i had one of those 12v tyre inflators lying around. i chopped the end of that would normally fit on the tyre valve and attached a length of hose to it. then i got an old bike inner tube and cut the valve out of that and attached it to the end of the hose. i think these valves are all the same and the threads are identical to the ones where the bleed nipple is on the calliper. all you have to do now is find a bolt the same thread as where the brake line goes and use it to block that off. a bit of wood in the middle works good (i 'borrowed' the top of my mams broom and it fit perfectly). it took over 150psi before all 4 pistons popped out.
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