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Disc Brake Calipers: Disassembly

WARNING: This page is about a different car, the 2006 Jeep Grand Cherokee. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Clamping Block of Wood Over Caliper Piston - Except SRT-10
GC0006270Courtesy of DAIMLERCHRYSLER CORP.
  1. Drain the brake fluid from caliper.
  2. C-clamp (2) a block of wood (1) over one piston.
    Fig 2: Placing Wood In Outboard Shoe Side of Caliper - Except SRT-10
    GC0006271Courtesy of DAIMLERCHRYSLER CORP.
  3. Take another piece of wood and pad it with one-inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal.
  4. To remove the caliper piston direct short bursts of low pressure air  with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out.
    CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston.
    WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal injury.
  5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore.
  6. Move the padded piece of wood in front of the other piston.
  7. Remove the second piston using the same procedure with short bursts of low pressure air  .
    Fig 3: Removing Piston Dust Boots - Except SRT-10
    GC0006272Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove piston dust boots (2) with a suitable pry tool.
    Fig 4: Removing Piston Seals from Caliper - Except SRT-10
    GC0006273Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: Do not scratch piston bore while removing the seals.
  9. Remove piston seals (3) from caliper (1).
    Fig 5: Pushing Caliper Mounting Bolt Bushings Out of Boot Seals - Except SRT-10
    GC0006274Courtesy of DAIMLERCHRYSLER CORP.
  10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1).
  11. Remove caliper bleed screw.
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