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Thread: Brake caliper mounting

  1. #1
    Join Date
    Mar 2007
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    Brake caliper mounting

    Hi. I just replace the brake caliper because the old one is stuck.
    Anyway when I want to put back the caliper and new brake pads this hole (circlednon the picture ) where the bolt go into stuck. It doesn’t move in and out so I can’t put the caliper because its too tight with the new brake pads on.
    Any idea how to unstuck this? Thanks


  2. #2
    Join Date
    Jun 2013
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    Quote Originally Posted by fourteen8 View Post
    Hi. I just replace the brake caliper because the old one is stuck.
    Anyway when I want to put back the caliper and new brake pads this hole (circlednon the picture ) where the bolt go into stuck. It doesn’t move in and out so I can’t put the caliper because its too tight with the new brake pads on.
    Any idea how to unstuck this? Thanks

    That is one of the caliper slide pin holes/guides, they get rusted up.
    But they also go back together before you put the pads in and put it back over the rotor, so it looks like it's being done a bit out of order.

  3. #3
    Join Date
    Oct 2022
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    If that pin is stuck, order up a new caliper carrier and sliding pin kit.

    My '04 had two pins stuck (not in the same corner), one I could get out and moving, one snapped in while I tried turning it to take out.
    .. that '04 had been sitting for ~7 or 8 years and neglected anyways.

    I put all four carriers and all the pins new, and pads. Still need to order up discs and calipers.

    Worth checking all the other sliders too!

  4. #4
    Join Date
    Apr 2016
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    if you want to try, you can unstick the current carrier/pin parts, but you need heat(easiest way).
    Two bolts hold the carrier bracket, so remove them and remove carrier. Set it up so you can heat up the carrier near the slide area, which will eventually release the pin.
    Then it needs a good cleanout inside the recess and clean the slide pin too. I've used various stuff to clean, they all work .. WD40, or brake cleaner or good old diesel.

    lube it up before you put it all together again.

    IIRC, the kit for each axle costs about $40-50ish(ie. all 4 pins per axle) ... handy items to replace every 20 years or so.
    Arthur.

    All these discos are giving me a heart attack!

    '99 D1 300Tdi Auto ( now sold :( )
    '03 D2 Td5 Auto
    '03 D2a Td5 Auto

  5. #5
    Join Date
    Mar 2007
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    I ended up ordering brake caliper carrier from uk. Hopefully they will come sometime next week. It is 23 yo so it it time to replace them.

    Thanks for all the replies.

  6. #6
    Join Date
    Mar 2023
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    Canberra
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    Had this happen to me. Sprayed it up with WD-40 and then managed to wiggle it free with multi grips. Pulled it out and greased it up. Fixed it up nicely.

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