A few tips to keep in mind while rebuilding brake calipers.
How to rebuild brake calipers so they last longer? First, of course, follow the instruction provided with your brake caliper rebuild kit.
Second, and also very important - don't forget about proper lubrication of all rubber components of the calipers. Using red rubber grease is the main tip of this articles. Red rubber grease is specifically formulated for lubricating rubber part in hydraulic systems. The grease is fully compatible with natural and synthetic rubbers on one hand, and compatible with brake fluids on the other. Further we will describe how to use red rubber grease in brake caliper rebuilds.
We will not describe how to do the actual rebuilding of the brakes, but instead we will concentrate on the finishing touches of the job.
The main point to keep in mind while rebuilding brake calipers is to keep everything clean and property lubricated. Keep the workplace clean, and use fresh brake fluid and brake grease.
To make the assembly of parts easier and ensure their long life, use red rubber grease for lubricating all rubber components of the calipers. Sometimes a sachet of red rubber grease is provided by the manufacturer together with the caliper rebuild kit. Most of the time the amount of grease provided is not enough. We recommend buying 1 ounce can of red rubber. This amount is enough for the job and you will not be tempted to use old grease and, probably dirty by then, if you buy a large can.
Thoroughly clean all parts before starting the assembly.
Lubricate piston seal with red rubber grease.
Smear inside of the caliper with grease.
Smear some grease on caliper piston.
Pack the dust boot with grease.
Now you are ready to start the assembly. Here, we are putting together a brake caliper from Triumph GT-6.
Insert the seal into the grove of the caliper bore.
Push the piston inside the caliper bore. We recommend to do this with your hands. Using a C-clamp or some other device to force the piston into the caliper may jam the piston and damage it or, alternatively, damage the walls of the caliper or piston seal or dust boot. Using rubber grease will make inserting the piston into the caliper very easy with your hands. Just push it down gently and make sure it is square in the bore. Once, the piston is half way in, place the dust boot around the piston and inset the dust boot lip into the grove in the piston. (By the way, be careful when puling the pistons out of the caliper during disassembly and don't damage the lip of the piston. A damaged lip may not seal well or, if it has sharp burrs it may rupture the dust boot.)
Push the piston in.
Wipe off the excess of grease from the caliper, dust boot and the piston. The job is done.