Articles: Peugeot 505:
Rear Disc Brake Caliper Repair [2/2]

Here is a repair kit of a different brand. Use brake grease to lubricate the new seals, piston and cylinder and insert them to grooves in the cylinder using the fingers only. If brake grease is not available, dip the new seals in clean brake fluid. Note that in this picture below the piston is NOT yet in the right position where it should be when you are ready to install brake pads (the big groove in the end should be vertical).

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Put some good super adhesive grease under the dust seals to prevent dirt and moisture jamming the lever. The grease I used should be very resistant to water, salt, heat and cold and it should stay there because it's very sticky. I also used the same grease to the other side of the cylinder. Just make sure the dust seal will stay put (try to remove some of the grease if it won't). Some dust seals are better shaped than others.



A plastic spacer, a spacer rod and an installation kit for brake pads. There are two kinds of spacer rods. Early rods are round in section whereas later rods are oval. Because of that they are not interchangeable. These rear brake calipers from a 1981 STI have early type spacer rods.




Make sure that the ratchet teeth are aligned with the piston grooves before engaging the pistons. If they are not properly aligned and you force the halves together, the ratchet teeth will get broken. When the piston halves are completely together and entered into the cylinder, turn the piston 1/8th of a turn (45 degrees) to engage the ratchet teeth. Now the piston is turned in the right position (the big groove in the end should be vertical) so that you can install brake pads. The brake pad has brackets that will fit to the groove on the piston.


Put some copper paste etc. between moving parts in the frame and to threads of bleeding screw.


New mounting bolts (hex head, 1,25 mm thread). Old bolts were very rusted and tight. There was no chance getting those bolts opened with regular tools. Heads of the bolts were quickly rounded. Finally the only way to get them loose was to weld proper extensions. It took quite much time and attempts before they were finally off because there wasn't much room to use the welding machine and it was difficult even to reach the bolts with the welding gun. Apply some thread locking compound to mounting bolts.


Before installing the calipers to the car, excess grease should be wiped off so that it won't foul the friction surfaces. Also use some solvent to degrease the discs. After installing brake calipers it is time to bleed the hydraulic system and adjust hand brake cables.


After over 20 months the brake calipers are still working properly and the epoxy paint has prevented them from rusting.


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