How-To: Rear Brake Caliper Overhaul

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MinkelR
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How-To: Rear Brake Caliper Overhaul

Postby MinkelR » September 10th, 2015, 5:24 am

Rear brake calipers are a little more complex to rebuild than front calipers. The calipers in the G1 Integra have an internally actuated parking brake that pushes the piston out a few millimeters. These parking brakes are prone to seizing due to water contamination or brake fluid leaking past the internal seal into the parking brake compartment. A rusty caliper piston will also cause the caliper to seize. The entire rebuild of the rear caliper will hinge on the condition of your caliper piston. Replacement rear pistons are not easy to get a hold of on the consumer market. If yours is too pitted, purchasing a commercially remanufactured caliper is virtually your only option.

Parts Needed:
Rear Caliper Seal Kit
Piston (If you can find one)
Brake Fluid
Silicon Grease

Instructions
1. Remove caliper and put it on a bench vise.
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2. Using a pair of needle nose pliers, twist out the piston by turning it counter-clockwise. Use the needle nose to fit in the grooves on the face of the piston.
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3. Using a pair of 90-degree snap ring pliers (Honda has a specific tool) remove the internal snap ring from the piston bore. Pull out the parking brake screw.
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Hondas Special snap ring tool
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4. Remove the rest of the assembly if it did not come out with the screw. You will need to remove the old piston seal to pull this out.
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5. Using a pair of needle nose pliers remove the pill shaped piece of metal that pushes out the parking brake screw.
It's way back there:
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Here it is:
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Bore is now clear:
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6. Remove the parking brake spring, nut, and lever.
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7. Pull the parking brake cam straight up to remove it.
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Notice the wear on the back of the cam from the internal needle bearings. If they dry out this can happen. A bit of 2000 grit sandpaper will smooth it out well enough to be reused.
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8. Using a flathead screwdriver carefully remove the seal. I had to reuse this since it wasn't in my kit.
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You can now see the needle bearing inside of the caliper. This is pressed in and cannot be easily removed.
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9. Using a rotary tool with a wirewheel attachment clean up the piston bore seal and the dust boot groove.
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10. Clean the bore and parking brake compartment with brake cleaner making sure to remove any metal shavings and contaminated grease.

11. Clean the piston with a wire wheel and polish it with some 2000 grit wet sand paper.
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This piston had some very minor pitting but is useable. If there is too much pitting you need to replace the piston otherwise your caliper is only good as a core.
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12. Reinstall the parking brake cam seal and cam. Be sure to use lots of silicon based grease on the internal needle bearing. Place the pill shaped piece of metal back into the hole of the cam through the bore.
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13. Put new O-rings on the parking brake screw assembly and reinstall all the components back into the caliper bore. Place the piston bore seal in its groove. Be sure to lube these seals with brake fluid only! Using other lubricants may cause the seals to degrade. I've found pressing the snap ring into the piston with a flat head screwdriver works the best.
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14. Install the piston dust boot onto the piston making sure to leave a portion of the dust boot extend past the end of the piston.
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15. Place the dust boot into the bore and carefully push it into the groove in the caliper with a flat head screwdriver. If you're unsure if it's seated properly give it a slight rotation. The boot should sit level all the way around.
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16. Screw the piston clockwise to put it back into the bore.
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17. Reinstall the parking brake lever, nut, and spring. Use antiseize on the nut if you want to remove it next time.

18. Regrease your slider pins and reinstall your rebuilt caliper!
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1987 Acura Integra LS (Rest in Pieces)
1989 Acura Integra LS Daily Driver
1992 Mazda 323 (Sold)

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