Rebuilding front brake calipers?

[Flyman 27]

What is involved with rebuilding the front brake calipers on a '91?
Any special tools required?
Any pointers?

[-=Jeff=-]

are they leaking? Is there a reason you want to rebuild them?

[Flyman 27]

One of my coming winter projects is the front brakes, they are getting a little thin (less than 1/8"). I am installing stainless brake hoses, banjo bolts, bleeders, pads and planned to paint the calipers with epoxy. If it isn't too hard, I thought that the seals should be replaced due to age & miles.
The seal kits are cheap. I couldn't think of any reason not to do it.

[RussMcB]

If I remember correctly (it was 3 years ago), I had a hard time finding the caliper seals. That may have been because I didn't know the right vendors to try (I was a ZR-1 Newbie).

I'm just mentioning that in case you want to have them in hand before you start.

Rebuilding them isn't hard if you've done other calipers before.

[Flyman 27]

I've replaced calipers many times, but I have never rebuilt one myself.
I have rebuilt several sets of drum brake cylinders.

[onethumb]

I've done this twice---not on a Corvette, but on a Pontiac and also a 4 piston Alfa.

It's a pain in the rear. Set aside a good amount of time & beer, and make sure there are no small children present.


That said, if you go slow, make sure the pistons and bore are smooth and that you don't add any additional grooves while assembling/disassembling, you'll be ok. Make sure the piston seal is not twisted when you put it on, and make sure you don't damage it, as this can cause it to leak.

Any corrosion in the bore or on the piston below the seal is a problem you'll have to fix. The surfaces of both should be smooth to the touch, like a stainless steel countertop. You can polish out some imperfections, but anything that emery cloth won't take care of should be rehoned or replaced.


Once you have done this job, you'll never do it again. The money spent on rebuilt calipers is more than worth it :)

Just my $0.02!

[TX '90 ZR1]

Here's a good source for brake parts. They also have some other corvette stuff.
They seem to fly under the radar on here, but I have had good luck dealing with them.
Lonestar Caliper Co.
903-829-8400
Guess it's OK to mention them on here.

[RussMcB]

I've done this twice---not on a Corvette, but on a Pontiac and also a 4 piston Alfa.

It's a pain in the rear. Set aside a good amount of time & beer, and make sure there are no small children present.


That said, if you go slow, make sure the pistons and bore are smooth and that you don't add any additional grooves while assembling/disassembling, you'll be ok. Make sure the piston seal is not twisted when you put it on, and make sure you don't damage it, as this can cause it to leak.

Any corrosion in the bore or on the piston below the seal is a problem you'll have to fix. The surfaces of both should be smooth to the touch, like a stainless steel countertop. You can polish out some imperfections, but anything that emery cloth won't take care of should be rehoned or replaced.


Once you have done this job, you'll never do it again. The money spent on rebuilt calipers is more than worth it :)

Just my $0.02!A bunch of good advice there. It is a job I never look forward to. There are probably lots of You Tube videos to watch.

One tip that was useful the last time I did it was to use a small amount of air pressure to get the old pistons out, but you need to stop them from coming all of the way out because once a piston is out you can't use air pressure to get the others out.

The reason I chose to rebuild rather than buy was to use the Doug Rippie aluminum pistons which probably help for track days. Otherwise I'd lean heavily towards buying rather than rebuilding. And there's probably nothing preventing you from painting purchased calipers.

Oh, and the rear calipers are usually more difficult because of the emergency brake parts.

[WARP TEN]

On my '93 I upgraded from stock calipers to the '96 grand sport calipers (which were stiffer--less caliper flex on hard braking) plus SS brake lines and Hawk pads. They were a direct bolt on replacement for the stock calipers. Improved the pedal feel and the braking was otherwise fine. You might be able to find them reasonably priced (On internet for around $50 each or more depending on source) without going through the hassle of your own rebuild of the stock calipers. --Bob

[Flyman 27]

On my '93 I upgraded from stock calipers to the '96 grand sport calipers (which were stiffer--less caliper flex on hard braking) plus SS brake lines and Hawk pads. They were a direct bolt on replacement for the stock calipers. Improved the pedal feel and the braking was otherwise fine. You might be able to find them reasonably priced (On internet for around $50 each or more depending on source) without going through the hassle of your own rebuild of the stock calipers. --Bob

Sounds like a good upgrade!
Do I use '91 or '96 GS caliper mounting brackets? Pads?
What about the rears?

[-=Jeff=-]

GS calipers bolt in using same brackets and pads as the 91 calipers.. main difference is the face of the Caliper with 'CORVETTE' on it and the structure of the caliper was improved.

Warp Ten was referring to $50 for the regular replacements.. GS calipers will be a bit more money

http://www.vettemod.com/forum/imagehosting/24c462be296be8.jpg

http://www.vettemod.com/forum/imagehosting/24c462be2489e9.jpg

http://www.vettemod.com/forum/imagehosting/24c462be1d3c87.jpg

[DRM500RUBYZR-1]

While you CAN rebuild them, I agree with the others, why?
I can likely make a cinder block, but if I only need two or three, much easier to buy them.
Cannot sing the praises of Lonestar enough!
Bair's also!
Jeff and Warp Ten are spot on in recommending the Grand Sport calipers, unless you are going NCRS, although I would still use the GS calipers and take the points deduction.
For looks alone, but they are better also which Jeff nicely pointed out.
A VERY GOOD upgrade!
Enjoy your project!!!!!!!!!!!!!!!
Marty

[Hib Halverson]

It's only the 96 GS front caliper which is stronger. The 96 GS rear caliper is the same except for the black powder coating.

Front calipers are pretty easy to rebuild provided you have rebuild kits and the FSM. Actually, given regular brake system flushes, you'll find the calipers will have little wear except, if you drive hard, the front outer caliper dust seals may be burned or melted.

Rear calipers are a little more difficult because of the caliper-lock parking brake. Again, the FSM is your friend.