R6 blue dot caliper rebuild on 87 Venture

[Bounder]

I am replacing the original front brake calipers on my 87 Venture with R6 blue dot. The original calipers started leaking after installing Galfer steel brake lines. Rather than rebuild I am replacing with R6. I have R6 calipers with pads from Ebay. As delivered there is not enough space between pads to fit on the rotors so I would like to disassemble and clean pistons. Can someone tell me how to remove pistons and reinstall to the flush position? Thanks

[bongobobny]

I use various thicknesses of wood and an air compressor to extend the pistons out uniformly until they start to pop, then carefully with a rag and pliers pull them out the rest of the way being VERY careful not to scratch the surface of the pistons, as even a small scratch can lead to a leak...

[CaseyJ955]

The gold dots are aluminum pistons but blue dots are steel, but they are still easy to mar with pliers so as mentioned be very careful. For removing my pistons I used a piece of wood and a small electric air pump, just put the fitting against the brake inlet with a rubber grommet and they slide right on out. once they are a ways out you should be able to wiggle them out with your fingers if you can get a nice firm grip. Make sure any seals and pistons you remove go back in the hole they came out of.

 

I cleaned the pistons with green scotchbrite pads and brakeclean spray stuff. I also carefully removed the forward seals, cleaned them up and put them back. I used a brush and more brakeclean to clean up inside the bores. Prelubed with DOT and reassembled carefully. I used R6 blue dots also and Galfer fully sintered pads and she stops like a MF with very little effort. Not grabby but definitely powerful and easy to use.

[Bounder]

Thank you both for the advice and the quick response. I am going to use the pads that came with the calipers for now as I am taking an extended trip and don't have time to wait for new pads right now. They have 1/16 to 1/8 remaining. Will the calipers with new pads fit over the stock rotors on my 87?

[camos]

Thank you both for the advice and the quick response. I am going to use the pads that came with the calipers for now as I am taking an extended trip and don't have time to wait for new pads right now. They have 1/16 to 1/8 remaining. Will the calipers with new pads fit over the stock rotors on my 87?

If the pistons on the new calipers will not press into the caliper there is a good possibility they may get sticky on your trip. If that happens the pads could wear out before the end of the trip. It may not be necessary to replace the pads immediately but before starting an extended trip it would be a good idea to make sure the pistons are working freely otherwise you might find yourself doing the job on the road.

[bongobobny]

Are you replacing the seals while you have the pistons out? That would be a great idea, and you would not have to worry about getting the pistons in the exact same location anymore as they would seat themselves to the new seals. They should be replaced as with age, the seals take on what is referred to as a "set" and have a permanent distortion (the main reason why Camos recommends returning the pistons to where they came from). Make sure the seal grooves are clean and free of any scratches as the scratches will cause a leak!!!

 

Yes, the R1/R6 calipers align right up with the MK2 rotors!

 

You mentioned that your old calipers leaked with the new SS lines. May I ask, did you replace both crush-washers when you installed the lines? You should NEVER reuse the crush washers as once you crush a crush washer it takes on a set to the surfaces they mate to, and may not crush again properly to the new surface...

[Bounder]

Thanks again! I did use new crush washers. I thought maybe increased pressure from steel lines caused seals to leak. Can anyone recommend a source for rebuild kit and new pads? And why HH pads?

[Condor]

Your blue dots should fit right on your '87 rotors. The pistons do need to be compressed back into the calipers. A large channel lock will do the deed.

 

Here's a pic of my '83VR with a set of blue's and '86 rotors.

 

[bongobobny]

Oh, your SEALS leaked! My bad, I thought you meant they leaked at the hoses...

 

Other than the usual dealers and boats.net etc, you could try member Skydoc_17 as a source. Earl is a great guy and does have some parts on hand. The reason for the EBC HH pads is they seem to work the best and last a long time...