How to Rebuild Brake Calipers

How to rebuild brake calipers on your vehicle. For this I’m using my 2006 Dodge Ram 1500 as an example, these are two piston calipers, however the same process still applies to single piston calipers too. Being that the truck is going through for a safety, these do need to be repaired. When I priced out new calipers, they were about $150 per side and a rebuild kit was about $20 per side. Calipers will need to be rebuilt if they’re leaking, sticking, or having ripped dust boots. #autorepair #brakes #howto
Here are the Amazon links for some of the products used in the video:
USA:
Scotch Brite green scuffing pad (600 grit): amzn.to/2MGpgxJ
Scotch Brite white scuffing pad (1200-1500 grit): amzn.to/2YM0cI9
Metal polish: amzn.to/3tytqIH
Brake cleaner: amzn.to/3df8FvQ
Steel wire brush: amzn.to/2Mx5F35
Brass wire brush: amzn.to/2MJM1ka
Copper washers metric: amzn.to/3u8DtUQ
Copper washers imperial: amzn.to/3s6W8Pn
Brake hone: amzn.to/3ppHxwn
Canada:
Scotch Brite green scuffing pad (600 grit): amzn.to/2MEQowT
Scotch Brite white scuffing pad (1200-1500 grit): amzn.to/3tvlAPL
Metal polish: amzn.to/3aACPGZ
Brake cleaner: amzn.to/3doe0AW
Steel wire brush: amzn.to/3cOcWpW
Brass wire brush: amzn.to/36P0jH6
Copper washers metric: amzn.to/2NvJF8S
Copper washers imperial: amzn.to/3asEX4F
Brake hone: amzn.to/3doeA1A
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Tools/Supplies Needed:
-wire brush
-brake cleaner
-brake fluid
-socket set and ratchet
-wrench set
-standard screwdriver
-new seals
-block of wood
-air compressor
-scuffing pads
Procedure:
Loosen the master cylinder to relieve any pressure. Use large interlocking pliers to compress the pistons if possible. Pinch the rubber flex line so the all the fluid doesn’t drain from this line.
Use the appropriate sized socket to break the bleeder screw free. Being that the caliper is being rebuilt, you can use a little heat from a propane torch.
Disconnect the brake flex line, have a drain pan ready to catch any dripping fluid. Using brake cleaner, wash the caliper to remove any dirt or brake fluid.
Use an air compressor, I set the regulator to 50psi. Make sure the bleeder screw is tight too. Keep your fingers far away from the pistons as they can come out with force and I’d also recommend wearing safety glasses.
Use wood or plastic to give the pistons something to hit against, don’t use the frame of the caliper or steel as it’ll damage the pistons. It helps if you have something wide enough where it can push both pistons out almost fully, that way if one sticks, you won’t have to struggle keeping the other in place. If one piston comes out too soon, then push it back in, then wedge it into place until the other comes out.
Remove the dust seals, these just fit into a slot and they can sometimes be stuck in place due to rust. Clean the pistons using brake cleaner, then inspect to ensure there’s no excessive rusting, pitting, scraps, or any other type of damage which can cause leaking or premature failure of the seals.
Wash the caliper with brake cleaner, removing any brake fluid. Clean up any loose rust and dirt using a wire brush and wash using brake cleaner. Use a standard screwdriver or scriber, some which can clean the groove sufficiently.
The standard screwdriver to remove the fluid seals. Gently remove then, don’t damage it’s slot as this can cause a leak. Use a 600 grit or higher scuffing pad to clean up the seal’s grooves. Use a 1000 grit scuff pad to clean up the pistons, removing any debris. Finish up with a metal polish to leave a clean finish which will ensure we have a good sealing surface and all the surface debris has been removed. Then give them a final clean with brake cleaner.
Only using brake fluid as a lubricate, anything else would cause contamination, apply it in the seal grooves and seals. Install the pistons, more brake fluid is applied to the outside surface where the seals will be in contact with.
Install the newly rebuilt caliper and tighten up those slide pin bolts. Reconnect the brake line and install new crush washers and torque the banjo bolts to the correct factory specifications. Then finally bleed the brakes, start from the furthest wheel first.
Thank you to all those who watch my videos and support my content. Don't forget to subscribe to my channel for future tutorial videos and like my video if you found it helpful. New videos are always being uploaded every week!
© 4DIYers 2013
All Rights Reserved
No part of this video or any of its contents may be reproduced, copied, modified or adapted, without the prior written consent of the author.

[@4DIYers]

Here are the Amazon links for some of the products used in the video: USA: Scotch Brite green scuffing pad (600 grit): amzn.to/2MGpgxJ Scotch Brite white scuffing pad (1200-1500 grit): amzn.to/2YM0cI9 Metal polish: amzn.to/3tytqIH Brake cleaner: amzn.to/3df8FvQ Steel wire brush: amzn.to/2Mx5F35 Brass wire brush: amzn.to/2MJM1ka Copper washers metric: amzn.to/3u8DtUQ Copper washers imperial: amzn.to/3s6W8Pn Brake hone: amzn.to/3ppHxwn Canada: Scotch Brite green scuffing pad (600 grit): amzn.to/2MEQowT Scotch Brite white scuffing pad (1200-1500 grit): amzn.to/3tvlAPL Metal polish: amzn.to/3aACPGZ Brake cleaner: amzn.to/3doe0AW Steel wire brush: amzn.to/3cOcWpW Brass wire brush: amzn.to/36P0jH6 Copper washers metric: amzn.to/2NvJF8S Copper washers imperial: amzn.to/3asEX4F Brake hone: amzn.to/3doeA1A

[@toyetoyetoye]

Not even a quarter of the way in and I am already blown away by the clarity, the information, the image quality. Good stuff!

[@4DIYers]

Thank you so much, really appreciate the feedback!

[@snarf114]

Have you ever considered being a flight attendant? You have the perfect voice for the pre-flight instructions.

[@BillClay88]

Never thought how simple rebuilding is. Sounds harder than it is. If piston is junk, not really worth it, but rarely is piston bad. Great job!

[@scrappy93]

I just stick disposable ear plug un the brake line hole over clamping since you can still damage the line.

[@Handofseeds]

That’s a good idea.

[@rngf_ashyxd860]

I let that shit leak on the lane way

[@Northwesternforcefield28]

Yeah the metal inside the brake hose.

[@ahahahahahaahahaa]

DUDE! The vise grips with rubber hose to crimp the hose so it dosnt leak is BRILLIANT

[@ua7pyro591]

Lol

[@donjulio5045]

Ancient Trick. But a good one

[@rodcaseracing3376]

It damages the hose and can cause a caliper to hang up

[@hs4a085]

Or you can tie the line upwards where it wont leak out

[@JackRR15]

I've got a better one for ya; before removing caliper, press the brake pedal down and hold it in place with a clamp or stick. It will prevent the fluid from draining from master cylinder. Granted you will have to let the line drain but it should stop. Prevents damaging the rubber hose.

[@barrykilts4506]

Finally,after watching a bunch of you/tubers someone does it right,thank you.I’m not a know it all but I am a back yard mechanic and this don’t require a brain surgen.

[@robertclymer6948]

Outstanding job and complete job. I have also seen the rubber boot slid over the piston before installing Per Eric the car guy. Thanks for sharing with us.

[@IppiopaidFEEDBACK]

Wow you are so systematic in your tutorial. This is going to save me money, because instead of buying a new callipers (which cost me $65 Plus $45 core charge, plus shipping $25) I’m now going to buy kits to the other three. Thanks!

[@4DIYers]

Thank you so much for the kind words and feedback! That'll definitely add up fast, happy to hear I was able to save you money.

[@wilfridrodriguez7954]

Excellent video on how to rebuild front brake calipers. Thanks for sharing

[@BrendonWBrown]

The rubberized needle nosed locking pliers is genius.

[@JAMAEL89]

Great job explaining and demonstrating procedures. Keep up the great work.

[@4DIYers]

Thank you so much!

[@thedevilinfrankenstein6503]

i was having a hard time with installing the new boots by myself. so i abandoned the job for today. i am glad i caught this video. awesome tips. I am definitely going to do this!! 😄👍

[@kwitwerikok8o863]

I struggled with the dust boot for over an hour. The boot must be on the piston and slid towards the caliper bore and near piston insertion end so that the boot will fit into it's caliper groove. The problem was that while trying to expand the boot to go in the groove it would slip off of the piston. I finally resolved the problem with a hose clamp lightly securing the boot on the piston and then expanding the boot to it's caliper groove. Once in the groove they do a good job of staying put. Then sliding in the piston and the outer boot into the piston groove is much easier. Hope this makes sense. The other piston and seals went as described in the video.

[@franklinstaana600]

This is a very informative article i love the way he presents this video

[@4DIYers]

Thank you so much!

[@LBZOverlander]

Thanks. I used your video to do my 06 2500 HD. Mine were much easier, I lubed up and pressed my cylinders in first. Then I added the dust boot last since you can tap/press in with a blunt flat punch tool.

[@JuanhCjbhvnbtrf]

Nice informative, detailed, and well explained video. Great work!!

[@okkrom]

I tried this once on a subaru. I never managed to get the seal, boot and piston back in place. Something would always pop out of place. You did a great job. I like to "hydrate" the rubber boots with silicone paste when I clean my brakes yearly.

[@HorizonFarming]

Oof, i'm about to do this on my Subaru😬

[@itszo4168]

currently doing this. I used a bolt and nut with the old brass washers to stop the fluid from coming out to much.

[@bwaccord99]

Excellent video. Clear information. Easy to understand. Good pace. Good video. Thank you!

[@4DIYers]

Thank you so much for the kind words and feedback, greatly appreciated!

[@flyntmyrick6291]

You made a very helpful and thorough video. Thanks for the information!

[@4DIYers]

Glad it was helpful and thank you for the feedback!

[@citrinwarren6073]

Great demonstration. I learned a lot lot from you. Thanks.

[@4DIYers]

Thank you so much, really appreciate the kind words!

[@JD-hy6yc]

Rebuilt are $180+, rebuild kit $4.82 for mine. Not even mentioning how my brake caliper has suicided and now my car can’t drive me to the auto parts store! I’ll definitely buy a couple rebuild kits to keep handy.

[@docimastic]

The first rate video, thanks so much!

[@devilin5237]

You are an excellent mechanic

[@4DIYers]

Thank you so much, greatly appreciated!

[@timoteooo94]

Damn so people just be wasting money buying new calipers….Glad to kno….You saved me alot of money

[@-DEATHSTROKE]

You can use Bendix brake grease for the rubbers installation so that brake fluid doesn't eat the painted calipers.

[@lashlarue7924]

Great tutorial! Thanks!

[@4DIYers]

Thank you!

[@ironmule4254]

Thank you for this video

[@Carlostype]

Just to add from my experience when pumping brake pedal try not to press down further than it normaly would during use as the master cylinder piston can score the seals, then you'd have a sinking pedal during braking, it's happened to me! Cheers mate, good info

[@4DIYers]

Great tip, thank you for sharing!

[@4DIYers]

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[@whiteboyfromernul]

i put wheel bearing grease around the bleeder screw so it cant suck air past the threads

[@frundlemud]

Good solid repair I'm sure you fitted the dustcap later.😊

[@4DIYers]

Thank you!

[@marcgingergagne6701]

Very Well done 👍

[@4DIYers]

Thank you!

[@truthsearcherforever3211]

I put 118psi n I busted my finger it shot like a bullet good thing it did not broke my finger. Rookie mistake. This was yesterday 3/8/2023. The piston roll down the hill when I drop everything because I was in extreme pain praying that my finger wasn’t broken I haven’t checked it yet hopefully it’s not all dinged from the fall.

[@ahahahahahaahahaa]

I find it easier to put the dust boot on the piston first. Just fyi. Great vid bro

[@4DIYers]

Thank you. Yeah I tried that, couldn't get it to seat on this caliper unfortunately.

[@jrcflaus]

10 out of 10!

[@dirtyaznstyle4156]

I’d just pump the brakes without the pads installed, those pistons come right out. Just stop before the seals let go and drain the caliper before pulling them the rest of the way out

[@yogibeer9319]

Jam up video! Thanks!

[@4DIYers]

Thank you!

[@dipndalip]

Thank you very much sir.

[@4DIYers]

You're very welcome!

[@XXxTheMaskedManXXX1]

I have the same exact truck where can I buy the seal kit and what is the part number?

[@4da626]

Where can I buy the sleeves for my caliper 2006 armada tried calling auto parts but nothing

[@uknowngamer1017]

I tried the compressed air strategy (before watching the video) and blew my dust boots out. They didn't even puff up, just *pop* quicker than I could know.

[@hnng3919]

What happened to the rings that secure the shield?

[@andrewdurfee2891]

On other videos i watched, they put the dust boot on the piston 1st & it seemed to reinstall easier

[@4DIYers]

Depends on the design. I tried both methods, the one I showed in the video was by far the easiest for me.

[@gregorymahnken9682]

Great video, very helpful. Noticed my boot is ripped when doing my last brake job. Caliper is $95, new boot and seal are $2.15. Any tips on removing and reinstalling the piston when it is a twist-in style?

[@kevinfisher3663]

GREAT VIDEO!!!!!!!!!!

[@4DIYers]

Thank you!

[@ibrahimantondalo9184]

good job

[@4DIYers]

Thank you!

[@lulubliz6405]

Good Video - but don't vise the grip brake line. Try an old valve stem in bango bolt hole, if you don't want all brake fluid to leak out😊

[@JaimeBlanco666]

Thanks! You just saved me $90+ for a new caliper and days of waiting for it to arrive.

[@4DIYers]

Awesome to hear and thank you for the feedback!

[@mguerramd]

Once you finish all the cleaning and are starting to reassemble, switch to CLEAN gloves. Keep a clean microfiber towel at hand to clean your gloves if you contaminate them. You want your reassembly spotless.

[@4DIYers]

Excellent tip, thank you for sharing!

[@jellyandme]

...what happens if the brake fluid gets on the discs and pads?

[@emangee9268]

If brake fluid falls on your brake rotor or brake pads this may cause resistance on the friction that the brake rotor and the brake pads are supposed to create. Spray pads and rotors with brake cleaner if brake fluid gets on em.

[@freelanceminion7396]

So the whole piston has to come out if you just want to replace the dust boot? There is no way to leave the seal and remove and replace JUST the dust boot?

[@4DIYers]

There are some commenters who have been able to replace the dust boot while the piston is in place, this will depend on the design.

[@scottnusser6232]

Nobody has or even show listing for rebuild kits😢

[@bucko1508]

I bought a set of used Brembos, decided to rebuild them. When putting back on of the pistons, I stupidly forced it in and now it won't go back in. Im thinking I need to try out this honing tool, but we will see.

[@4DIYers]

Sounds like the seal is binding.

[@RoyGarino]

awesome

[@4DIYers]

Thank you!

[@ksislobbishant5074]

lol I got a 06 ram 1500 as well.

[@JohnSmith-sf8gj]

I'm disgusted at how few auto parts retailers actually stock caliper rebuild kits in favor of full replacement.

[@4DIYers]

I couldn't agree more, companies just want people to buy new parts and stuff is far from cheap anymore. Every dollar counts, we try to save where we can.

[@petesanchez3786]

What kind of table that you're usingWhat

[@4DIYers]

It's the tailgate on my truck.

[@ivlark1]

Rubber hose or cardboard in a pinch :)

[@andrewdurfee2891]

Aren't you supposed to use grease on your pistons???

[@4DIYers]

No, it'll contaminate the brake fluid. Only use brake fluid.

[@andrewdurfee2891]

@@4DIYers that's what I thought, but on another video the guys rebuild kit came with a little packet of grease & he rubbed it all over the piston 🤷🏼‍♂️

[@mittortz]

This part confused me too. I just rebuilt my calipers, used permatex silicone ceramic extreme brake lube on the sealing washer and piston, according to other videos I had watched. Hoping I don't run into issues.

[@paulb8186]

Forget the compressor just use the power of the hydrolic fluid and press the brake pedal with the caliper detached but still connected to the fluid line.

[@bmfilmnut]

It's a brake hone, not a brake cone.

[@4DIYers]

I said hone, not sure where you heard cone from.