3rd Gen caliper repair (vids and pics)

[KERRSURF]

I should probably supply subtitles for this.

I had a sticking piston in one of my calipers, I was changing the top and bottom ball joints and track rods so took the opportunity to get the brakes working as they should. I still had very effective braking as the piston would move out but not return fully which cause the pad to wear unevenly.

shopping list.
new piston
new caliper seal kit
new track rods
new discs
new pads
new brake pin kit
new balljoints, upper and lower.

So after stripping everything and breaking a few of the smaller bolts I drilled/ tapped and sorted out the offending rusty beggars, replaced with quality stainless fixings.

In the caliper I used an airline to get all the pistons moving out then replaced them and used a steel tube section to hold them in while I used the air method to blow out the stuck piston. It doesn't take much pressure and it can also be done with a grease gun but you would need to ensure the caliper internal spaces were cleaned out properly before re-fitting.

Vid of piston popping out. There was no need to screw the airline onto the caliper, just hold an air pistol against caliper.

Click video to play.

[KERRSURF]

I cleaned up the pistons that were removed and checked for damage, as suspected one of them had a pitting and this was caused by the dirt seals being perished and letting the road salts damage the piston.

Click video to play.



Easing out the pistons after they have been freed of with air method. when a piston pops out it needs to be cleaned and replaced then clamped in place to allow the others to be blown out. Then you can just grip them and slide them out once they are all free.
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Pic of piston damage.
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New top and bottom balljoints in place. The top ones have to be pressed out and pressed in, around 2 tons should do it. Thanks to Stevie for letting us use his bearing press.
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[KERRSURF]

All new brake parts arrived today, so up and running again tomorrow.

[si tate]

All new brake parts arrived today, so up and running again tomorrow.

You hope.

[KERRSURF]

With these old trucks you always need hope and luck bro.

[si tate]

With these old trucks you always need hope and luck bro.

A little skill come in handy too.

[KERRSURF]

Aye, got a wee bit of that, thank fook I have a bit of luck too.

[KERRSURF]

Put everything back together today, new piston working perfectly.
ABS light was on though so investigated and found one of the sensors hadn't seated properly, all sorted now.

The lads at the garage who fitted the new steering arms nearly had the truck on fire trying to heat the locknuts, but they won in the end, all aligned and driving sweet.

Ready to go camping adventures now.

[si tate]

Coolio.

[The Gov]

Very handy thread that mate thanks for taking the time to share i with us all, where did you get the caliper seal kit from please ?

[KERRSURF]

Brake parts superstore. One of the lads provided a link on My thread in the General section. On page 3 now, titled .caliper exchange/overhaul. Member wishbone provided the link to Land Cruiser spares that match the Surf. I'll post more details when I get home, on My phone at the moment.