Stuck caliper piston(s)
 

I've never rebuilt a caliper before - read about it- been a service writer & manager & watched while my guys rebuilt calipers,been the dummy to help bleed the brakes, quite often too.

Anyway, i am in the process of going through my recently inherited 911 brakes. Dad had the car since new and did his best to keep the car up, not himself, but paid a lot to keep in good shape - his baby - and i was 600 miles away, so only got to offer advice rarely. He was an engineer and devoted to the car and i am honored to now move the car foreward.

So, while attending to other issues, i noticed that the right front caliper semed to be sticking and my mechanic buddy, (hero with a lift) and i spoted the sloppy left rear "A" arm busihing. After going further with the inspection, i noticed that the rear spring plate/torsion bar caps were up against the covers, that i decided to do the full on brake and suspension overhaul.

I bought Elephant's fornt and rear bushings, EBC yellow stuff pads, new wheel bearings, Bilstein HD shocks, caliper overhaul kits and stainless lines and i am on my way...

The loose LF torsion bar was rusted and groved from the worn out bushing, so i got another from Parts Heaven, at Chucks recommendation.

After disassembling the brakes, one of the rotors was at the throw away thickness, the other close, so, so i ordered a set of zimmerman zinc plated rotors.

While trying to disassemble the front calipers, i popped out one piston, with air, then reinserted it to try to get the other piston out. I held it in place with my, not inconsidrable body weight, while applying 125 psi air - no go a few times.

After a couple of fine IPA beers, i recalled my good budy's recommendation of a grease gun, so, i zipped up to the local Napa and bought a short chunk of bubble flair line, a zerk fitting and a compression coupler to pipe fitting, so i could fit the zerk.

Not very elegant, i held the "lose" piston in the caliper with a couple of pry bars and C clamps, (trying to keep the piston square in the bore, so as not to F up the bore or piston), screwed in the bubble flare adaptor assembly and proceeded to pump grease into the caliper - and watched the grease unstick the stuck piston - with no violent piston ejection.

Once again, old age and science, triumph over mother nature's corrosion, years and dirt.

With malice afore thought, i am fortunate to remain, chris. http://forums.pelicanparts.com/uploa...1350783465.jpg
http://forums.pelicanparts.com/uploa...1350783501.jpg
If this didn't work, i was going to "sik" the kitty on the whole thing.
http://forums.pelicanparts.com/uploa...1350783634.jpg

Yep.

Did this with my 356 SC front calipers.

Just slowly pops them...........My dad told me to do it this way.

You could have been even more savvy and just screwed the grease gun threaded end directly into the calliper... they're a direct match ;)

http://forums.pelicanparts.com/uploa...1350801752.jpg

And I bought a grease nipple...............*slaps forehead..........

Oh !!!!
I'v just had the same problems on 3 of my callipers.
I friged about with them and gave up. there is! the safety issue as well.
So I replace the 4 callipers, new cross drilled discs, pads, and front wheel bearings,
jepers it's good now, the braking is strong, smooth and predictable. down side $$$$
My advice just replace them.
Steve.