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removing stuck brake caliper pistons removing stuck brake caliper pistons
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  #1  
Old 10 Apr 2007
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removing stuck brake caliper pistons
I have 6-pot Tokico calipers. I've pushed the pistons out as far as I can, then split the caliper. How do I get the pistons out without damaging them? To give some context, only 2 pistons moved 'freely'. The dust seals have been dragged out as the remaining 4 pistons grudingly emerged from the caliper.

Are Tokico's particularly bad for corrosion?

cheers,
Doug
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Old 11 Apr 2007
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Compressed air
Make sure the pistons are facing down and give the inlet hole a blast of compressed air. This used to work for me on car calipers, so I see no reason why it will not work on your jambed pistons.

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Old 11 Apr 2007
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Alternativly if you don't have a compressor to hand grab 2 tyre levers or similar - put a bar between them so the ends lever outwards and place inside the piston cavity - make sure the caliper is held solid and pull - generally works with the most stubbon of pistons.

So lever
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------------/ |
o |
------------\ |
--------

and pull.
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Old 11 Apr 2007
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Talking Brake pistons
When I am repairing brakes I try to first pump the pistons with the master cylinder. Pull the caliper off the disc then fill the master cylinder with brake fluid and pump. If one piston comes out right away put a spacer in it so it doesn't come all the way out and lose pressure. If you pump all the cylinders almost all the way out and clean the crud off them then push them back in lubed with brake fluid the next time they should come out. Did I tell you about the time I was test riding a honda with a stuck front brake and the front wheel locked up? Not a pretty sight but the ringing in my ears is supposed to go away soon.
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Old 13 Apr 2007
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"Alternativly if you don't have a compressor to hand grab 2 tyre levers or similar - put a bar between them so the ends lever outwards and place inside the piston cavity - make sure the caliper is held solid and pull - generally works with the most stubbon of pistons."

That's the best tip I've heard in ages, thanks. 5 pistons popped out, one is still jammed in. So I'll put it all back together and use the brake lever to force it out. But I was well impressed with the tyre lever approach, I used steel bicycle lever from Halfords, £2.99.

cheers,
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Old 15 Apr 2007
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Old 15 Apr 2007
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Quote:
Originally Posted by DougieB View Post
"Alternativly if you don't have a compressor to hand grab 2 tyre levers or similar - put a bar between them so the ends lever outwards and place inside the piston cavity - make sure the caliper is held solid and pull - generally works with the most stubbon of pistons."

That's the best tip I've heard in ages, thanks. 5 pistons popped out, one is still jammed in. So I'll put it all back together and use the brake lever to force it out. But I was well impressed with the tyre lever approach, I used steel bicycle lever from Halfords, £2.99.

cheers,
Cool - I'm glad that worked for you - I'm all for cheap simple solutions :-)
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Old 16 Apr 2007
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Saddle stems and handlebar stems from a bicycle (no ahead set MTB type! :-) work like a dream.
Find what fits best into the caliper. Bar end weights work for small stuff and scooter crap.
if your piston puller is a bit thinner than the piston put a strip of aluminium sheet metal in between.
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