Loosen banjo bolt and disconnect the brake line from the caliper.
3. Lay the caliper on a padded surface (Shown is a Porsche 997 front 6 pot caliper).
Many sub-components attached to OE piston can be turned into one solid piece of stainless steel RB piston.
STEP 2 - GETTING READY FOR INSTALLATION:
Place several pieces of wood or cardboard inside the caliper which will act as padding when the pistons are ejected from the caliper.
Induce compressed air (80-90 psi) into the caliper via the banjo bolt thread hole to eject the pistons from the caliper, several attempts with clearance adjustment by cardboard may be required.
Remove pistons from caliper carefully pulling them out by hand or a plier.
4.Remove old seals from piston housing with a thin and flexible metal blade (Such as a .009"/0.23mm feeler gauge) to gently pry the old seal out. If you must use a pointy pin, be careful not to damage the housing.
5. Clean the housing and grooves (seal & boot) with compressed air. 6. Inspect piston housing and pistons (if pistons are being reused) to make sure the piston has no visible damage eg. scratches and/or corrosion. 7. Test fit the new pistons that can go into housing with a proper clearance - Not too tight & not too loose to make sure the new pistons are in the right size.
STEP 3 - OIL SEAL INSTALLATION:
Slightly stretch the new seals (stretch @ every quarter turn), this will ensure to better seat inside the seal groove.
WARNING: Do not OVER-STRETCH or they may not fit into seal grooves.
2. Place oil seals into grooves. 3. Apply brake grease inside the seal as lubricant for piston installation "After" seal is inside the seal groove - Do not apply grease all over the seal before.
Step 4 - PISTON & DUST BOOT INSTALLATION:
Caution! NEVER lubricate the boot. If you are installing the high temperature (Blue) boot, you must avoid it contacting with BRAKE FLUID or the blue boot will break due to material incompatibility. This is why we recommend use only brake grease instead of brake fluid as lubricant - In case of mis-contacting.
Pull dust boot over piston in a downward motion so the seal inside diameter is properly fitted into piston neck.
2. Push piston into caliper housing with a perfect straight and even downward motion - NEVER crooked, if you feel resistance DO NOT force the piston in - Back up and re-check to ensure the seals are installed properly inside the seal groove i.e. the seal is "concentric" with the housing. This is a very important step to avoid the piston cuts into seals and ruin your rebuilding job. 3. Press down on outer dust boot surface so that is evenly seated into boots housing grooves.
Step 5 - COMPLETION:
Re-attach caliper to adapter/bracket & spindle/upright.
Reconnect the brake line.
Bleed the system.
Test drive the car at low speed to make sure the calipers are functioning properly.
When installing high temperature (Blue) dust boots, extreme caution must be exercised from avoiding contact with brake fluid, and never use brake grease, or it will damage the boots causing per-mature failure like this Focus RS customer.