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(Hopefully) Helpul tip on caliper rebuilds Posted by ryan [Email]  (#2222) [Profile/Gallery]
(more from ryan) on Sun, 15 Apr 2012 22:38:54
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I just got done rebuilding the calipers on my Viggen; disassembled, cleaned, honed the bores, cleaned again, reassembled. Everything is easy, except installing the dust boots. The boots need to seat on the outside of piston and the inside of the cylinder (both in their respective grooves). However, you cannot fit the boot over the piston when it's already set in the cylinder (I even tried a 360º shoe horn with an old [cut up] sour cream container - that won't do the trick either) . Nor can you seat the boot in the cylinder once it is set on the piston. What you are left with is putting the boot over the piston (but not set in the groove) and trying to seat the boot in the cylinder, but the caveat is that the piston cannot be in the cylinder at all. In this case, the boot will always slip off the piston in the effort.
Long story short, save yourself a lot of time by taking a little time to tape the boot to the piston, then release the tape when the boot is set in the cylinder. In my case, I had packed the boot full of grease prior to fitment, as instructed, so I had to clean the boots and pistons up really well so that the tape would adhere to both the piston and the boot.
Because the boot was now slipped on, and it had no grease inside, I had to find a new way to get the grease in there. I found an unused dental syringe (which was supposed to be for flush water when I had my wisdom teeth removed), and was able to lift up the dust boot and inject grease in there. Prior to finding that syringe, I was planning on buying a cooking-type marinade injector, which I imagine could work, but the tip would have been larger.
Any way, this is exactly the advice I could have used earlier today, so I thought I'd post this on here. Good luck!
posted by 67.160.8...
, Sun, 15 Apr 2012 22:38:54 <-- Viewing This Message, Mon, 16 Apr 2012 09:45:18, Tue, 17 Apr 2012 08:49:54
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