Brake Caliper Rebuild - Rear

This procedure covers the complete disassembly, cleaning, inspection, and rebuild of the rear brake calipers on a 2018-2024 Honda Accord with 1.5L turbo engine, including seal replacement and proper reassembly.

Warnings

Tools required

Parts

• Rear brake caliper rebuild kit (includes seals, dust boots, and internal components) × 2 — Use Honda OEM 06435-T2A-A01 or equivalent
• Copper crush washers for brake line banjo bolts × 4 — Use OEM specification
• Silicone brake grease (high-temperature) × 1 — Honda Silicone Grease 08C30-B0234M

Fluids

• DOT 3 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake (front wheels only on this FWD model)
2. Loosen rear wheel lug nuts while vehicle is on ground, do not remove
3. Raise rear of vehicle with floor jack and secure on jack stands at proper jacking points behind front jack point
4. Remove rear wheels completely
5. Use turkey baster or fluid extractor to remove brake fluid from master cylinder reservoir to prevent overflow during caliper piston compression
6. Place cardboard or drip pan under work area to catch brake fluid
7. Have all rebuild kit components, tools, and fresh brake fluid ready before disassembly

Procedure

1. 1

   Remove rear brake caliper assembly
   Place brake fluid catch container under caliper. Using flare wrench, loosen the brake line banjo bolt at the caliper (do not remove completely yet). Remove the two caliper bracket bolts (14mm or 17mm depending on model year) that mount the entire caliper bracket to the knuckle. Note that these are high-torque fasteners. Once bolts are removed, carefully disconnect the brake line banjo bolt completely, allowing fluid to drain into container. Immediately plug the brake line with a rubber cap or wrap in plastic to prevent contamination. Remove caliper and bracket assembly from vehicle.
   ⚠Brake fluid will drain when line is disconnected. Have catch container positioned before loosening banjo bolt.
   Torque spec

   Bracket Bolts97 Nm (71 lb-ft)
2. 2

   Separate caliper from bracket and remove brake pads
   With caliper assembly on clean workbench, remove the caliper slide pin bolts (typically two bolts). Separate the caliper body from the mounting bracket. Remove brake pads and any anti-rattle clips or shims, noting their orientation for reassembly. Set bracket aside if not servicing the slide pins.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Remove caliper piston using compressed air
   Place several shop towels inside the caliper to cushion the piston. Position a wooden block or dowel against the piston face. Connect compressed air nozzle to the brake line inlet port on the caliper. Apply air pressure gradually in short bursts. The piston will be forced out by air pressure. Control the piston movement with the wood block to prevent damage. Once piston is out, remove dust boot and piston seal from caliper bore using plastic pick or seal removal tool. Do NOT use metal tools that could scratch the bore.
   ⚠️Piston can eject forcefully under air pressure. Always use wood block to control movement and keep hands clear of piston path.
   ⚠Never use excessive air pressure. Start with low pressure and increase gradually if needed.
4. 4

   Clean and inspect caliper components
   Thoroughly clean the caliper bore, piston, and all internal passages with brake cleaner and lint-free towels. Inspect the caliper bore for any pitting, scoring, corrosion, or damage. Minor staining is acceptable, but any scratches, grooves, or corrosion requires replacement of the entire caliper - do not attempt to rebuild. Inspect the piston surface similarly. Clean the exterior of the caliper body. Use wire brush to clean mounting surfaces on the bracket.
   ⚠A damaged caliper bore cannot be safely rebuilt. Any pitting or scoring can cause seal failure and brake fluid leaks.
5. 5

   Install new seals and prepare piston
   Remove new piston seal and dust boot from rebuild kit. Lightly coat the new piston seal with clean DOT 3 brake fluid. Install the seal into the groove in the caliper bore, ensuring it seats completely and evenly without twisting. Clean the piston with brake cleaner and dry completely. Lightly coat the piston surface with clean brake fluid.
   ℹ️Do not use any lubricants other than clean brake fluid or specified silicone brake grease on internal brake components.
6. 6

   Install piston and dust boot
   Carefully insert the piston into the caliper bore by hand, aligning it straight to avoid damaging the new seal. Use caliper piston tool or C-clamp to slowly press piston into bore, ensuring it moves smoothly without cocking to one side. Press piston until it bottoms in the bore. Install the new dust boot by fitting the inner lip into the piston groove and the outer lip into the caliper body groove. Ensure boot is properly seated all around with no twists or folds.
   ⚠Piston must enter bore perfectly straight. Cocking the piston can damage the new seal and cause leaks.
7. 7

   Service caliper slide pins and bracket
   Remove slide pins from caliper bracket (if equipped). Clean slide pins and bores thoroughly with brake cleaner. Inspect pins for corrosion or damage and replace if necessary. Inspect slide pin boots for tears or damage and replace if compromised. Apply thin coat of silicone brake grease to slide pins (not conventional grease). Reinstall slide pins into bracket with new boots if needed.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
8. 8

   Reassemble caliper to bracket
   Install brake pads into caliper bracket with anti-rattle clips and shims in original orientation. Position caliper body over pads and onto bracket. Install and hand-tighten caliper slide pin bolts. Apply small amount of silicone brake grease to slide pin bolt threads. Torque slide pin bolts to specification.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
9. 9

   Install caliper assembly to vehicle
   Position caliper and bracket assembly onto rear knuckle mounting surface. Install bracket mounting bolts and hand-tighten. Torque bracket bolts to specification in cross pattern. Install new copper crush washers onto brake line banjo bolt (one on each side of banjo fitting). Connect brake line to caliper and install banjo bolt, torquing to specification if you have the value, or snug firmly by hand (typically 25-30 Nm, but verify in service manual as this is not in provided spec list).
   ⚠Always use new copper crush washers on banjo bolt. Reusing old washers can cause brake fluid leaks.
   Torque spec

   Bracket Bolts97 Nm (71 lb-ft)
10. 10

    Bleed brake caliper
    Attach clear hose to bleeder screw and submerge other end in container with clean brake fluid. Have assistant pump brake pedal 3-4 times and hold pressure. Open bleeder screw 1/4 to 1/2 turn while pedal is held down. Fluid and air will evacuate. Close bleeder screw before pedal reaches floor. Repeat process until clear fluid with no air bubbles flows from bleeder. Maintain master cylinder fluid level throughout bleeding process. Final torque bleeder screw to specification.
    ⚠️Never let master cylinder reservoir run dry during bleeding or air will enter the system.
    ⚠Do not overtighten bleeder screw - it can easily strip or break.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Repeat for opposite side
    Perform steps 1 through 10 on the opposite rear caliper. Rebuild both rear calipers as a matched pair to ensure even braking performance. After both sides are complete, perform final brake system bleeding starting from the caliper farthest from the master cylinder (typically right rear, then left rear, then right front, then left front).
12. 12

    Reinstall wheels and perform final checks
    Reinstall rear wheels and hand-tighten lug nuts in star pattern. Lower vehicle to ground. Torque wheel lug nuts to specification in star pattern. Pump brake pedal slowly until firm pedal is achieved (may take 10-15 pumps). Check master cylinder fluid level and top off with DOT 3 brake fluid to MAX line. Inspect all connections for leaks.
    ⚠️Do not drive vehicle until brake pedal is firm and you have verified proper brake operation.
    Torque spec

    Wheel Lug Nuts108 Nm (80 lb-ft)

Reassembly

1. After bleeding is complete, pump brake pedal 15-20 times to ensure proper piston positioning
2. Top off master cylinder reservoir to MAX line with fresh DOT 3 brake fluid
3. Verify no brake fluid leaks at caliper connections, banjo bolts, and bleeder screws
4. Clean any spilled brake fluid from wheels, calipers, and painted surfaces immediately

Verification

• With engine off, pump brake pedal multiple times - pedal should become firm and hold pressure without sinking
• Start engine and verify brake pedal does not sink when pressure is applied
• Check for any brake fluid leaks around calipers, brake lines, and bleeder screws
• Test drive in safe area at low speed (under 10 mph) to verify brakes engage properly and vehicle stops straight without pulling
• Perform several moderate brake applications from 25-30 mph to seat pads and verify normal brake operation
• After test drive, recheck all torque specifications and inspect for leaks
• Monitor brake pedal feel for first 50-100 miles and recheck fluid level after first drive

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