Jim and Sunil, thanks for the responses. Since I don't have experience doing this, I'm wondering if there is a procedure for it in the shop manuals (I'm doubting it since they expect the mechanics using those manuals are experienced) or maybe in the Haynes manual. I'm great a disassembly, but a procedure is always welcome to cover the things that experience teaches.
...Kevin Jim Cathey said: >> The '79 240D project car for my son has a leaking left front caliper. >> Bought a rebuild kit from Rusty. Any tips or pitfalls that I need to be >> aware of? This is my first time rebuilding a caliper so any tips >> appreciated. > > It's easy and fun! No real pitfalls, I use 600-grit wet-and-dry > sandpaper in a bucket of water to clean gunk and corrosion off of > the pucks and out of the bores. Work parallel to the sealing rings, > not perpendicularly. You don't want scratches (and there shouldn't > be any) in a direction that will encourage leaks. > >> make sure you have an air compressor to blow out the pistons. doing >> it any >> other way is hard. Also, fit the rubber boots to the pistons BEFORE >> you > > I've done this, but its scary and a little bit dangerous. Compressed > air really bangs the pucks out of there, you need wood to catch the > puck against. I've chipped a puck before doing this, and people have > been hurt too. > > Much better is to drive them out with the brake system, though that > takes > a bit of fiddling to get the second puck out. Or you can do as I did > recently and use a water-filled grease gun to do the job. Tres cool! > And totally safe. http://cathey.dogear.com/mb190d.html > > I still use the air compressor, but only to dry things off. > >> slide the pistons into the cylinders. Once the pistons are totally >> seated, >> it's really hard to fit the boots on. > > Just put 'em on before you fully seat the pucks. You don't have to put > them on before you start to insert them, unless you find that to be > easier for you. > > -- Jim > > -- "Thank God for Microsoft" -- Linus Torvalds
