Editing How to Rebuild a Brembo Caliper (section)

=== Disassembly ===

[[Image:Brembo_Caliper_7.JPG]]

Unscrew piston as far as it will go using either a windback tool or stout needle nose pliers, one tip in each hole. Push in and rotate counter clockwise.


[[Image:Brembo_Caliper_8.JPG]]

As the dust boot stretches, pull it out of the groove.
The piston can be pried out with two screwdrivers. An internal snap ring holds it tightly, so be prepared to try a few times and apply some effort. Before it pops, it will feel “springy.” When the snap ring does pop, the piston will go flying, so put a rag over it to keep it from falling. You can use a socket on each side to support the screwdriver.


[[Image:Brembo_Caliper_9.JPG]]


Here’s the prying position (without the dust boot and rag). From this image you can get a perspective of how far up the piston will rise without coming out. The piston can also be removed with air pressure into the brake line supply inlet.


[[Image:Brembo_Caliper_10.JPG]]


Once the piston is out, do not turn the caliper over. There are several loose pieces inside that may fall out.


[[Image:Brembo_Caliper_11.JPG]]


NB Only follow the following procedure if you have access to a new screw as 80% of the time they shear off & are not available to buy separately. You can get the whole assembly with the snap-ring out of the bore with some curved tools (eg. bend a screwdriver ) so it comes out as 1 piece. (Courtesy of Arno) 

Remove the dust boot.
With a 4mm allen key, remove the screw. This screw has an O-ring around the head, so do not reach in and use pliers. It is also held in with thread lock glue, so it feels a little stuck before it comes loose. It may also drag the whole way out. Use the proper allen key, since the metal is soft and you’ll easily round the hole.


[[Image:Brembo_Caliper_12.JPG]]


After the screw is removed, the threaded disc can be unscrewed and removed. This disc pushes on the inside of the piston when pulling on the parking brake.


[[Image:Brembo_Caliper_13.JPG]]


Without the disc, a ball bearing race, a snap ring, and two washers will be visible in the bore. Turn the caliper over to remove them.


[[Image:Brembo_Caliper_14.JPG]]


Here’s what will fall out:-

Ball bearing

Flat washer

Wave washer

Snap ring


[[Image:Brembo_Caliper_15.JPG]]


Removing the worm thread shaft is next.
Look down into the bore for the internal snap ring. It has several tabs bent to point up at you. With a flat screwdriver, pry the tabs at the ends of the snap ring towards the center of the bore and disengage it from the groove in the wall. 


[[Image:Brembo_Caliper_16.JPG]]


Now the worm shaft (and snap ring) can be removed. Notice the tabs.


[[Image:Brembo_Caliper_17.JPG]]

Unscrew the hex stop peg in the boss of the caliper.  You will need a 4.5mm allen key which is an uncommon size.

In case the grub screw/peg strips and you need to drill it out, the following diagram shows the sizes:

[[Image:Grubscrew-brembo.jpg]]

By drilling (or preferrably milling) out at 9.5mm the threads should be spared and after drilling through deep enough the tapered section should be cut free and can be re-used with a normal M10x1.00 grubscrew to re-seal the hole. The remains of the thread can be picked out and cleaned up.

[[Image:Brembo_Caliper_18.JPG]]


Remove the parking brake lever, parking brake shaft dust seal, and push the shaft into the caliper body.
The flat washer tends to stick in the caliper, be sure not to miss it.


[[Image:Brembo_Caliper_19.JPG]]


Remove the ball bearing drive plate, the needle bearing, and the flat washer.
Remove the old piston seal.