Re: '92 100S brakes

[e6941tb@gnn.com]

> The job wasn't too hard, and I didn't have a manual.  It took me about 45 min
> a side.  The problem I had was that I couldn't get the piston to compress back
> into the caliper.  I ended up removing the caliper and disassembling it on
> the bench to see how it works.  The piston is connected to a course threaded
> rod, and is simply screwed back in.  At least that's what I did on the bench.
> When I tried this on the other side, it spun but didn't go back in.  I ended
> up removing this one, too, and then it threaded back in.  It took me a while
> to bleed the brakes, but then I figure that most of the brake fluid was
> changed in the process!
> 
> I'm still not sure what the trick is to screwing the piston back in...

You either need an Allen socket, or a special "two horn" tool. I had to
machine mine out of a 2" round stock  of mild steel, having carefully
measured the mating piston surface beforehand.

The piston will not go in, unless you apply some pressure to it. I use a
C-clamp with my tool. I first tighten up the clamp, then turn the tool
1/2 of a turn, then tighten the clamp and again go 1/2 of the turn.
10min per side.

To remove a caliper from the car and take it apart in order to replace
the brake pads? That's crazy.
I mean, I do it all the time, when there is a need to rebuild the damn
thing, but not on a simple pad replacement!

E-mail me if you need a drawing of the tool that I've made. In this case
you will have an option of fabricating it before you take the caliper
off a carrier bracket for the next brakes replacement.

Igor Kessel
'89 200TQ