Caliper Rebuild Question
 

My brake caliper rebuild is going nicely.

The only snag are the rear outer seals. I can not get them over the boss on the caliper body. When one side is down the other slides off :rolleyes:

There is a beryllium copper(?) strip with little teeth that grip the boss. It looks good in theory, I can't quite seem to make it happen.

Any suggestions?

85
911
Carrera

Aston

I just rebuilt my 83 911 calipers by following the Pelican link http://www.pelicanparts.com/techarticles/911_caliper_rebuild/911_caliper_rebuild.htm.

Didn't have any issues except hard lines, one of which I had to replace.

I didn't understand your comment:

The only snag are the rear outer seals. I can not get them over the boss on the caliper body. When one side is down the other slides off

And the term Boss

Can you restate the problem?

The rear dust boot seals the region between the piston and the caliper body.

I can get the seal to seat on the piston no prob...but step 2 is the tough part: seating on the caliper.

I just did a complete set on my '69 w//o problem. Maybe put the seal in a pan of how water to make it more pliable??????

BTDT. I got the dust covers on using blocks of wood but I wouldn't say it was "easy". I've heard Gerber baby food jar lids do the trick nicely but I've never tried it; it just sounds right. Here's a link to someones solutionSmileWavy The last post.

http://forums.pelicanparts.com/porsche-911-technical-forum/62850-brake-rebuild-dust-covers.html?highlight=brake+rebuild

I figured it out - piece of cake when you know how.

The food jar lid gave me the idea. I got an 1 1/2 pipe fitting (end cap) which has an OD of 56.5mm. The wall was a little thick so I ground it down with the Dremel to give an ID of 50mm.

Perfect fit, one good squeeze and the seal is on!!!

Thanks.

Another solution
 

I found that a front inner wheel bearing race from my '84 Carrera is the perfect size to seat those pesky rear caliper dust seals.
Why I saved it, you ask? I thought it might come in handy for something. And it did!
Wife hates that!