try this technique i discovered.

 

The Helm's manual does not specifically show how to rebuild the caliper's.

 

EXACTLY what I needed, thanks

 

i'm bumping this old thread because i've got my calipers off to powder coat, and could use a little help getting the rears apart. does anyone have any experience with this? i've got the pistons out and all of the hardware off the outside, but it looks like i need to pull a spring clip out to get the internal mechanisms and the rubber gasket apart.

 

my2ks2k,
Great question.
I am at the same place with my rear calipers in getting them ready for powdercoating. Anyone have a DIY for getting the internal mechanisms and the rubber gasket apart?

 

too late, i already did it; i'll draw a pic and describe getting it apart in a few

 

ok here's a quick drawing of what the guts of the rear caliper look like:


after the retaining ring comes out, everything else basically pulls straight out with a little wiggling. the picture shows the order that the pieces are in there, but i believe you can just grab the threaded piece and pull and all the pieces on top of it will come out at the same time. the piece on the bottom left of the picture is a brass looking piece, and pulls out from the side and then you can pull the rubber gasket out.

after all these pieces come out, you'll notice that there are still bearings that the brass piece sat in; i couldn't tell if that would come out without being destroyed, so i left it in, and after baking the powder it didn't seem any worse for the wear. i plan on putting some more grease in there in case any of it baked out, but otherwise it seems fine to me.

IMPORTANT: i sandblasted the front calipers to prep them for powder coating, but if you leave the bearings in the rear calipers, you DO NOT WANT TO PUT THEM IN A SANDBLASTER. no amount of taping/sealing/covering will save you from getting grit in there. use a wire brush instead.

 

my2ks2k,
I am glad you got yours apart and thanks for sharing the diagram.
I will give it a shot this weekend and see if I run into any issues.

Did you have any problems trying to re-assembly the parts after the calipers were powder coated?

 

always glad to help if i can

so far i've only got one front caliper back together, i just got the rebuild kits in yesterday.
i don't anticipate having any trouble, other than the normal difficulty of getting a caliper back together. one thing to note, powder coat does not like brake fluid; i coated mine gloss black, and there are some spots on the one i got back together (luckily on the back, out of sight) where some fluid got on it and took the shine off. other than that, shouldn't have any problems. i'll let you know once i know for sure.