Brake Caliper Rebuild - Front

Complete rebuild of front brake calipers including disassembly, seal replacement, piston cleaning, and reassembly to restore proper braking function.

Warnings

Tools required

Parts

• Front brake caliper rebuild kit (seals, dust boots, piston seals) × 2 — Use OEM Honda caliper rebuild kit or equivalent
• Silicone brake grease (high-temperature) × 1 — Honda silicone brake grease or equivalent
• Brake cleaner spray × 1 — Non-chlorinated brake parts cleaner
• Threadlocker (medium strength) × 1 — Loctite 243 or equivalent

Fluids

• DOT 3 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level ground, place in Park, and engage parking brake firmly
2. Loosen front wheel lug nuts 1/2 turn before raising vehicle
3. Raise front of vehicle with floor jack and support on jack stands rated for vehicle weight at designated front jacking points
4. Remove both front wheels completely
5. Clean brake caliper exterior with brake cleaner to remove road debris and contamination
6. Prepare clean workspace with lint-free towels, organize rebuild kit components, and verify all seals are present
7. Place brake fluid catch container under work area

Procedure

1. 1

   Remove caliper from bracket
   Attach bleeder wrench to bleeder screw and open slightly. Use a catch container as brake fluid will drain. Remove the two caliper slide pin bolts (17mm socket) from the rear of the caliper. Lift caliper off the brake rotor and bracket. Once caliper is free, close bleeder screw. Support caliper with wire or bungee cord if brake line is still attached, or proceed to disconnect brake line at the caliper banjo bolt (use two wrenches to prevent twisting the line).
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
2. 2

   Disconnect brake line and drain caliper
   Place catch container under caliper. Using 12mm flare nut wrench, carefully loosen and remove the brake line banjo bolt from caliper body. Remove and retain the two copper crush washers (discard these, new ones should be in rebuild kit or purchased separately). Allow remaining brake fluid to drain completely from caliper into catch container. Cap or plug the brake line end to prevent contamination and further fluid loss.
3. 3

   Remove caliper piston
   Place caliper on clean workbench with piston facing up. If using compressed air method: thread compressed air fitting into bleeder screw port or brake line port. Apply compressed air gradually at low pressure (30-40 PSI maximum) while keeping fingers clear of piston. Piston will slide out of bore. If using manual method: use caliper piston removal tool per tool instructions. Remove piston completely and set aside on clean towel.
   ⚠️Keep hands and fingers completely away from piston during air pressure removal. Piston can eject with significant force causing crush injuries.
4. 4

   Remove old seals and dust boot
   Using plastic pick or seal removal tool, carefully pry out the dust boot from the caliper bore groove. Remove the piston seal from its groove inside the caliper bore using pick tool, working carefully around the circumference. Do not scratch or gouge the caliper bore surface. Remove any additional seals or O-rings present. Discard all old seals.
5. 5

   Clean and inspect caliper bore and piston
   Spray caliper bore thoroughly with brake cleaner and wipe with lint-free towel. Inspect bore for scoring, pitting, rust, or corrosion damage. Light surface rust can be polished out with crocus cloth using circular motion. Deep scoring or pitting requires caliper replacement. Clean piston exterior with brake cleaner and inspect for chrome plating damage, scoring, or pitting. Any piston damage requires new piston or complete caliper replacement. Dry all components completely with compressed air or lint-free towels.
   ⚠If caliper bore shows deep scoring, pitting beyond 0.5mm depth, or significant corrosion, do not rebuild. Replace entire caliper to ensure safe brake operation.
6. 6

   Install new piston seal
   Coat new piston seal from rebuild kit lightly with clean DOT 3 brake fluid. Carefully install seal into the groove inside the caliper bore, working it in with fingers around entire circumference. Ensure seal is fully seated in groove with no twists or folds. Seal should sit evenly in groove all around.
7. 7

   Install new dust boot and piston
   Coat caliper bore lightly with clean brake fluid. Install new dust boot into outer groove of caliper bore, ensuring it seats fully. Coat piston exterior generously with clean brake fluid. Carefully insert piston into caliper bore at a slight angle, then straighten as it enters. Push piston in gradually, ensuring dust boot lip engages properly with piston groove. Continue pushing piston until approximately 10mm of piston extends from caliper bore. Verify dust boot is properly seated in both caliper and piston grooves with no folds or pinches.
8. 8

   Rebuild second caliper
   Repeat steps 1 through 7 for the opposite side front caliper to ensure even brake performance and matched caliper condition on both sides. Mark or tag calipers for correct side reinstallation (driver/passenger).
9. 9

   Reconnect brake lines
   Install new copper crush washers on both sides of brake line banjo fitting. Position caliper and thread banjo bolt through washers and brake line fitting into caliper body. Torque banjo bolt to manufacturer specification (typically 34 Nm/25 lb-ft, though not in provided spec list - consult service manual for exact value). Do not overtighten as this can damage crush washers and cause leaks.
10. 10

    Reinstall calipers to brackets
    Clean caliper slide pins thoroughly with brake cleaner. Apply thin coat of silicone brake grease to slide pin shafts (not threads). Position caliper over brake rotor and align with bracket slide pin holes. Install caliper slide pin bolts and torque to specification. Verify caliper moves freely on slide pins with no binding.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Bleed brake system
    Starting with the wheel furthest from master cylinder (typically passenger rear), bleed entire brake system using two-person method or vacuum bleeder. At each caliper, attach clear hose to bleeder screw, open bleeder 1/2 turn, and pump brake pedal until fluid runs clear with no air bubbles. Close bleeder screw while pedal is depressed. Repeat for all four corners ending at closest wheel (typically driver front). Top off brake fluid reservoir to MAX line with fresh DOT 3 brake fluid between each wheel.
    ⚠Never let brake fluid reservoir run dry during bleeding process or air will enter the system requiring complete rebleeding.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Reinstall wheels and perform final checks
    Reinstall both front wheels, starting lug nuts by hand. Lower vehicle until wheels just contact ground. Torque lug nuts in star pattern to specification. Lower vehicle completely and remove jack stands. Pump brake pedal firmly 10-15 times until pedal feels firm and reaches normal height. Check brake fluid level and add if needed to MAX line.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all caliper slide pin bolts are torqued to specification with silicone brake grease applied to pins
2. Verify brake fluid level is at MAX line in reservoir with fresh DOT 3 fluid
3. Confirm no brake fluid leaks at banjo bolt connections or bleeder screws
4. Verify brake pedal is firm and maintains pressure when depressed for 30 seconds

Verification

• With engine running, apply firm brake pedal pressure - pedal should be firm and not sink toward floor
• Check all caliper mounting points for proper torque and no looseness
• Inspect for any brake fluid leaks at caliper connections, bleeder screws, and brake lines
• Perform low-speed test drive (under 15 mph) in safe area to verify brakes engage smoothly without pulling to one side
• After test drive, re-inspect all connections for leaks and verify pedal remains firm
• Perform 3-5 moderate brake applications from 30 mph to properly seat new seals before normal driving
• CRITICAL: If brake pedal feels soft, spongy, or sinks during application, do not drive vehicle - rebleed brake system completely or have professionally inspected

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