How could i remove part Nr. 15 ? It sits thight inside the brake caliper body and just moves barely (Propably hold in Place by the O-Ring). Tried to remove it gently with long nosed pliers, no chanche..

 

Maybe a pick tool?

 

Sorry, I forgott to Mention: Tried a pick tool also. I stopped before braking the tip of the tool.

 

Watched some Youtube video. Nr. 15 is really hold in Place only with the O-ring, but it sits thight. Best way is to tap the whole brake caliper on the Workbench until it falls out. Will see....
This is really not a work for beginners, and not fun. Next time i will try to get overhauled brake calipers. My ambition to do maintanance on the car by myself has found its limit here.

 

Just pull it out with needle nose pliers. I've completely disassembled and re-assembled 2 rear calipers already, and just took apart a 3rd yesterday for a buddy.

 

I tried it, but no luck. My pliers sliped.
BUT: There is a tiny hole inside part 15. Secure the e-brake lever with a clamp, use a air gun with a long nozzle and just blow with compressed air into the hole. And "Pop".. its out.
I figured out how to re-assemble part 15 with the "pill" (part 14) in 30 seconds. I will post my solution with pictures this week.

 

Getting that pill to seat back into the lever cup properly when re-inserting the threaded worm screw assembly is a real pain in the dick. I used a generous amount of grease to hold the pill upright as I fed the screw assembly back into the caliper....what a nightmare.

 

Here is my way:
- Fit the E-brake lever with spring, so that the lever is hold in Postion.
- Place the Caliper in a vise (or vice), upwards and straight
- "Glue" part 14 to 15 with brake caliper grease
- Use a magnetic hand and carefull place part 15 from above into the caliper. Done. I have done it two times, it worked perfect. Fits at the first try in seconds. No hassle, no swearing.

 

Nice job! Hope your weather improves so you can go to the English gardens!

 

Thanks Jim. Yes,the weather was horrible. I just read the news here in Bavaria, we had the coldest, rainy and windy April, March und May since 25 or 75 years, depending wich weather condition counts.
14 frozen days in April, 22 rainy days in March, May also, plus strong winds. People really started to become bitchy and angry. 3 Months of bad weather in a row gives you a bad mood.

1 1/2 tank fills with my S 2000 so far and 108 Km with my Kawasaki... 60 in the rain because i had to do the mandatory safety inspection.
The best i could do was to work in the garage and overhaul the brakes with no hurry. At least try to make the best out of the mess.