How To: Rebuliding Z32 calipers

Post by **94_240sx** » Mon Nov 27, 2006 9:49 am

Here we go guys. I did it over the weekend. I have 30mm aluminum calipers. Somehow I ended up with brand new caliper for the driver's side and used one for the passenger side. This is a picture of used one.
Modified by 94_240sx at 12:19 PM 11/27/2006

Post by **94_240sx** » Mon Nov 27, 2006 9:50 am

Remove clip from 2 pins in the back. Pins that are holding pads will slide out from the front.

Post by **94_240sx** » Mon Nov 27, 2006 9:51 am

Pads, clips and pins will come out easy and they will look like this.

Post by **94_240sx** » Mon Nov 27, 2006 9:52 am

If you just want to replace worn out or torn boots, you don't need to go further. Just remove boots, clean up and reinstall new boots, clips and pins that are included in most rebuilding kit.

If you want to powder coat your calipers, move on!!! I used breaker bar to remove big 4 bolts in the back. I stepped on the caliper and did this.They were bolted on pretty tight.

Post by **94_240sx** » Mon Nov 27, 2006 9:55 am

Then remove 'O' clips and rubber boots that protect the pistons. You will also see 2 small 'O' rings between two halves. Everything's out except pistons in below picture.

Post by **94_240sx** » Mon Nov 27, 2006 9:56 am

Now, it's time to remove the pistons. I spoke with 4 different powder coating shops and all of them asked me to take the pistons out, so I can tell they don't want to powder coat calipers with pistons in.Front half has 2 holes and the back has 3 holes. One on the back is for the brake line. You block holes and blow air in using air compressor. I used hand held 2HP compressor and it worked just fine. Get a trash can and put some newspaper and towel, so piston won't get damaged. They will come out loud and fast.

Post by **94_240sx** » Mon Nov 27, 2006 9:58 am

****Watch out for knuckles****

One piston will come out first, so use vice to hold that one and pop the other one. You really have to be careful here. You don't want to get hurt.

Post by **94_240sx** » Mon Nov 27, 2006 9:59 am

Picture of back half. There are rubber seals in the middle of the cylinders, so don't forget to take them out. Be carefull and don't make any scratches on the cylinder wall.

Post by **94_240sx** » Mon Nov 27, 2006 10:00 am

I cleaned them up really good and shipped these 8 pieces to powder coating shop in NJ.

Post by **94_240sx** » Mon Nov 27, 2006 10:03 am

Came back like this one week later.

Post by **94_240sx** » Mon Nov 27, 2006 10:04 am

This is the kit that I got from Courtesy Nissan. This kit should be universial for all z32 front calipers. I had a used set of rear calipers, but they were in very good condition, so I didn't buy a kit for the rear.

Post by **94_240sx** » Mon Nov 27, 2006 10:09 am

New pistons, seals, boots, clips and 'O' rings...

Post by **94_240sx** » Mon Nov 27, 2006 10:09 am

This is the seal that goes in the middle of the cylinder.

Post by **94_240sx** » Mon Nov 27, 2006 10:10 am

Push the pistons back in like this.

Post by **94_240sx** » Mon Nov 27, 2006 10:12 am

Put small 'O' rings between 2 halves. Okay, here's the deal. These small 'O' rings were not included in the kit. I saw someone bought them from ACE Hardware store though. I just reused old ones. They seemed to be okay. You need to lubricate all the rubber parts BTW.

Post by **94_240sx** » Mon Nov 27, 2006 10:14 am

Install new rubber boots, big 'O' clips and 4 bolts to complete.

Post by **94_240sx** » Mon Nov 27, 2006 10:15 am

I asked power coating shop to shave off NISSAN logos and they came out really nice. I'm going to buy Hawk pads later, so my calipers stay this way for now.

Post by **ILikeMy240sx** » Mon Nov 27, 2006 10:19 am

This is an AWESOME WRITE UP!!!!

Nice job!

Post by **94_240sx** » Mon Nov 27, 2006 10:24 am

ILikeMy240sx wrote:This is an AWESOME WRITE UP!!!!

Nice job!

Thanks man. Please feel free to ask any questions.

Post by **Bumnah** » Mon Nov 27, 2006 12:51 pm

# to the powder coating shop, and price please.

those look nice.

Post by **94_240sx** » Mon Nov 27, 2006 12:59 pm

Bumnah wrote:# to the powder coating shop, and price please.

those look nice.

This is the place.

http://www.trgcoating.com

He charges $35 for each caliper, so I paid $140 for all 4 corners plus shipping. I used DHL Ground, and it was $11 from TX to NJ. I accidently hit one of the calipers with a tool and it didn't leave a single scratch or scar. Very strong finish and should last for a while. Other local shops were not familair with z32 calipers, so I didn't hesitate send them to trgcoating. He's very familiar with Nissan stuff.

Post by **whitetshirtguy** » Mon Nov 27, 2006 1:30 pm

how much did the rebuild kit cost i just need it for the front but yours look awsome and great write up and good pics

Post by EW » Mon Nov 27, 2006 1:33 pm

Nice write up.

Post by **AmoebAssassin** » Mon Nov 27, 2006 2:45 pm

What is the torque spec on the four connecting bolts that hold the two halves of the caliper together?

Post by **AZhitman** » Mon Nov 27, 2006 2:54 pm

Article-worthy!

Let me know what you want your "custom title" to be!

Post by **zenkii** » Mon Nov 27, 2006 4:15 pm

nice write up

Post by **gabossie** » Mon Nov 27, 2006 4:40 pm

Great write up! I need to rebuild my calipers and paint/powdercoat them black.

Post by **94_240sx** » Mon Nov 27, 2006 5:06 pm

whitetshirtguy wrote:how much did the rebuild kit cost i just need it for the front but yours look awsome and great write up and good pics

Thanks!!

Here's the seal kit(41120-30P25). It's only $30.44. Pins, clips and pin clips are like $5-10 for each or something like that.http://www.courtesyparts.com/M..._Code=

You can get them from PDM too, but I found Courtesy is cheaper. PDM charges $43.09 for the front seal kit which is 41120-30P25. http://www.pdm-racing.com/products/brakesz32.html

Post by **94_240sx** » Mon Nov 27, 2006 5:16 pm

AmoebAssassin wrote:What is the torque spec on the four connecting bolts that hold the two halves of the caliper together?

Very sharp!!! I don't know. I just torqued pretty good. Besides, I don't think you can torque them right on the ground. I don't think they will leak though. Small 'O' rings should be able to manage the pressure.

Post by **whitetshirtguy** » Tue Nov 28, 2006 5:55 pm

thank you and again great write up and they look awsome i wnat to see them on the car

How To: Rebuliding Z32 calipers

How To: Rebuliding Z32 calipers

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