4ank

Long story short, bought my BBK gently used in January of '07. Found out today that 1 piston on the passenger side is frozen. Need to figure out options quick.

Has this happened to anyone else???

4ank

Allout

Have you tried pushing the piston back in? If you have a vacume pump, I would try sucking the brake fluid out of that side of the caliper and push the pistons all the way back in. There may be some particles that have that piston hung up. Pushing the piston in while sucking the fluid may clear the object that's keeping the piston from free floating.

You can also call Rotora - I think they have rebuilt calipers also for our kits.

BTW - no problems with mine so far. I've got around 50K on mine and they seem to be working fine so far.

4ank

I have tried -- I did the other side with no problem and as you can see the piston to the right moved back easily.

I agree with you that there may be some particles that have the piston hung up, but I don't have a vacuum pump

smokendsm

iTrader: (1)

just wondering.. how much pressure are you using to push it back in? are you using a c-clamp?

4ank

Yeah -- I used a c-clamp and that thing was not moving at all. Like I said, I did the other side with no problem and the piston to the right moved with ease.

On other note, sorry I didn't get in touch with you, I was too pissed when I found this and wrapped everything up.

CleanCL

iTrader: (4)

needs to be torn down. send it to rotora.

jproy

try pressing the brake pedal to make the piston come out a little more then try to compress it again.

Allout

That's not a bad idea. Sounds like the piston is torqued in the cylinder.

jproy

I just realized how frickn worn out those pads are!!! WOW!! talk about waiting till the last minute? Your pistons must have been at there extended limit and the outer portions of the pistons probably had debris on them. That debris probably has them hung up. Press the brake pedal again to get the pistons fully extended or until they fall out. Clean the cylinders and then put it all back together and rebleed the system. That is worst case scenario but I think you should get the picture. I doubt your calipers and pistons are damaged. They more than likely just need to be disassembled and cleaned. You can get the rebuild kit from George at Rotora if you want to go that way but I would call him anyway to discuss it. Jim.

4ank

Yeah -- I can't figure out what happened first -- the piston getting locked up causing my pads to wear quicker or I just let the pads go that long. I talked to the shop where I take my car and he said the last time it was in, everything was cool.

MADMAN187

simple solution: move to the west coast

Harrisonk531616

theres two things you can do;
1.) Set the caliper back on to the Hub. Using a pry bar against the rotor and the seized piston, pry it back as hard as you can. (if your slapping on new rotors)
2.) Use adjustable plyer type oil filter wrench and squeeze it as hard as you can with bleeder valve open.

jproy

I wouldn’t squeeze the piston!!!!! If anything you want the piston to come out of the caliper. Forcing the piston into the caliper may cause whatever has seized the piston to do damage to the caliper cylinder bore, assuming its not torqued which I doubt. You want to get that debris out of the cylinder bore not force it in. Personally I would send your caliper to Rotora. It’s not worth it to damage it and they will fix it right. What is the word on this issue?

4ank

No word yet. Haven't heard anything from Rotora yet and haven't had time to look at it and try some of the things you mentioned. My step dad is a machinest so he said to take the caliper off and he would take care of it. I was hoping for an easier solution, but that might be what it comes to.

I want to see what Rotora can do for me though. I will check back with updates.

visuelz

Don't know if this may help but try spraying some WD-40 in between so it slides in and out easier.

4ank

Update: Called Rotora and talked to a guy Todd, good dude. He said that they can either send me the parts or if I ship it to them they will rebuild it. They charge $25 per caliper plus the parts (piston seal, dust boot, and/or piston). He said these parts are pretty cheap, so I think I am going to box up the caliper and send it to them. I pay shipping, but this is a lot better than I expected.

Now, the question at hand is when I remove my caliper, what are my best options in the meantime. Should I attach my stock caliper so I don't lose a lot of fluid (obviously, I would not drive it). Would I have to bleed the system?

LukeaTron

Just take the bolt with the holes in it (I can't remember what the hell they're called) to the hardware store and find a regular bolt of the same size. Get a matching nut and two brass washers. Put that on the end of the hose with a washer on either side of the fitting. Works pretty well.

You're still going to have to bleed the system when you put it all together no matter what, but the less air you get in there, the easier it is to get it all back out.

Oh, and if you have an air compressor, you can use that pop the pistons out. Put a piece of wood where the rotor would usually be so they don't fly out so hard and fast that they get damaged. Be very careful not scratch the sides of the piston or the cylinders.

smokendsm

iTrader: (1)

I like lukeatron's idea for stopping fluid loss. the bolt hes talkin about is the banjo bolt..

4ank

Finally got some time to play with this....

Worked like a charm....now it is a waiting game until the caliper gets back from Rotora

4ank

Finally got the caliper back from Rotora.

I bled the brakes, but only on the new caliper side. I am not driving the car yet, but want to know if I should just leave it at that or do the whole system. Does it really matter?

New Rotors + New Pads + Rebuilt Caliper =

smokendsm

iTrader: (1)

That looks sweet man!
I want a BBK! Let me test to see if my wheels will clear the calipers!

Allout

Depends on how the fluid looks. I would probably flush the whole braking system and be done with it for quite a while.

BTW - did you have both calipers rebuilt?

4ank

No, just the one -- looking back, I should have gotten them both done, but Todd @ Rotora recommeded just to get one done if I am having problems with it.

Allout

Todd seems to know his stuff so I would trust his opinion.

ljmushock