Stuck caliper piston(s)

[chrismorse]

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.

If this didn't work, i was going to "sik" the kitty on the whole thing.

[wasserkuhl]

Yep.

Did this with my 356 SC front calipers.

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

[Fishcop]

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

[wasserkuhl]

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

[SLR]

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.