CT200h - Brake Caliper Rebuild

Wanted to refresh the braking system but wasn't pressed for time so got a set of used caliper and set about refreshing it.

Parts used:
FRONT Brake Cylinder Rebuild Kit - 04478-47040
REAR Brake Cylinder Rebuild Kit - 04479-12230

Did a quick clean up by throwing it in the cuda that got rid of mostly all the grime etc. that had built up over the years and prepped them with a quick sanding and cleaning out all the crevices before it went for paint.

Picked a color that would tie in to the 'Hybrid' logo on the side of the car.

Masked up all the any mounting surfaces and the insides of the caliper. All OEM parts were used for this rebuild.

For the rear caliper if you press down on the bracket where the ebrake cable connects to it slowly pushes the piston out, you can do that till it pops out or out enough where you can pull it by hand.  

Pulled the brake pins out and cleaned out the pins and where it slides in the caliper. Used a brass brush and brake cleaner. The pins were regreased and new rubber boots for the pins were used. 

To push the piston out from the front caliper I used a Milwaukee inflator with the nipple attachment. I put some foam between the piston and caliper to cushion the piston when it came out, then pressed the nipple against where the brake line threads in, set the inflator to 7psi to push the piston out, pull out if it comes out too fast. Do this at your own risk, I assume no responsibility, I'm just stating what I did. 

I used a composite pick to mitigate the risk of any marring to the piston of cylinder. With all new piston rings, boots etc. I went ahead and ceramic coated it because umm.. why not.  

Everything looks good and I did a basic test by pushing the piston out slowly as described before and back in hopefully everything works. For now everything looks good, if I was in a hurry would I do this again, absolutely not. This whole process probably took a month or so just because everything was done when I was bored. Thanks to Jeremy at the body shop for painting these for me. 

-AJ Abraham

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