Thread: Small D2 brake caliper repair. (rubber boot)

I have a heap of photos of how I did a calliper rebuild. I came up with some tricks. In the mean time call Ken at Karcraft and he will hook you up with a genuine reco seal and boot kit. Not to hard a job. I'll upload the pics later as a bit of a how to.

Originally Posted by mattg

I have a heap of photos of how I did a calliper rebuild. I came up with some tricks. In the mean time call Ken at Karcraft and he will hook you up with a genuine reco seal and boot kit. Not to hard a job. I'll upload the pics later as a bit of a how to.

Thanks mate,

I'll search Karcraft.

Happy Days

Also DONT buy a Britpart reco kit it will only end in tears

Originally Posted by mattg

Also DONT buy a Britpart reco kit it will only end in tears

Oh yeah, Fully aware. I ended up with a set of their watts linkage bushes. It wasn't by choice. They haven't lasted 5,000km maybe 4,500km if they're lucky.

Happy Days

Piston needs to come out IIRC , so get boot and seal. Urea based grease to lubricate. You can use an airline to blow the pistons out, but a piece of wood in the caliper to catch them. Don't use your fingers, it hurts ...
Genuine are best and should be a finger fit, but make sure you get the piston in square, they are a close fit.

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Thanks for the idea to use air to push the piston out. I'd still be pulling on them without that information. I use a shrader valve I have in my emergency SLS repair kit. I just screwed it in and pumped them out with a foot pump. Good word on using a piece of wood to catch them too. The pistons put a slight dent in the radiator pine 2x1 I used.

So I have emailed Karcraft and got a price for the seal kits. I have now emailed them again and asked for shipping cost and how they wish to be paid. I will just do both front and rear while I'm going.

I have now found I need one front piston and a rear slide as well.

Happy Days.

Originally Posted by steve_a

Urea based grease to lubricate.

Can you tell me more about this Urea grease, where to get it and where to use it. Is it rubber safe for the boots?

Happy Days

Ceramic High Performance Synthetic Lubricant | Bendix Brakes

This has always worked for me, urea based is ridiculously priced iirc