JasonGhostz

The problem part is OEM PN 43233-S04-003, and is for a 99-00 Civic SI Rear Brake Caliper (or compatible). The Caliper Body is completely broken down except the Piston Sleeve (and rubber seal), Parking Brake Shaft, and Parking Brake Shaft Rod.

While rebuilding my left rear caliper, I hit a brick wall. The Piston Sleeve (#16 http://www.slhondaparts.com/im...3.jpg ) is stuck to the inner bore, and won't come out. I've tried everything from sweettalk to death threats, but it doesn't seem to respond. The Sleeve will move around, so I know it hasn't completely rusted frozen. There seems to be too much pressure from the rubber bushing for it to free up, AS WELL AS hydraulic resistance from the Parking Brake Shaft (I can hear air moving through the "seals"). The sleeve will move, but the outter most rim of the sleeve can never get past the Circlip Groove before the resistance stops it.

I've given it a few whacks with a BFM (rubber version of the BFH), as well as my fists, my head, and my neighbor's cat. The expletive-er won't budge!!!

I've already soaked the bore with PB Blaster, WD40, 3-in-1, and Brake Fluid. Nothing has worked yet. I have several other rust removal products, but do not want to use them yet. They might cause the sleeve to fuse to whatever's giving me the resistance, but I will consider this as a later option.

So I've tried to pull it out using the adjusting bolt & its washer, but there's just too much resistance. Every time I try it, the bolt simply comes free without the sleeve attached. I've tried to glue the bolt to the sleeve, but the glue never dries completely (I'm using water-based glue). I've tried super-gluing it as well (it will scrape off of metal with a wire brush), with the same results.

One of the things I have left to try is fitting dental floss deep enough into the bore to get under the sleeve, and wrap it around well enough to try to pull it out. The only other thing I can think of is using an Air Compressor to fit over the banjo bolt, and giving large bursts of air to try to shoot it out (while looking down the bore without safety glasses and the parking shaft pointed at my nuts .. this thing is driving me THAT crazy). I will post results of the flossin' afterwards.

But other than giving in to the forces of the almighty wasted dollar, I can't think of anything else...

And this is why I come to you, my noble HT-ers. While the help and suggestions are always appreciated, please keep the "Damn, dood... that sucks ", "Just buy a new one", and "Go with the 40/40 Prop Valve" posts to a minimum. If there's a simpler solution, please LMK.

TIA, Have a great drive!
JasonGhostz

JasonGhostz

Man... Don't tell me I've stumped all you gurus... Maybe all I need is a lil'

... BUMPPPP!

I'll be going for my last "Super-Glue the Adjusting Bolt to the Piston Sleeve" attempt before I go with the floss. My fuse is running short...

TIA
JasonGhostz

JasonGhostz

Well, first off. Thanks for all the help! lol.. I finally got the stupid expletive-er out!

FREEEEEEEDOMMMMMMM!!

My final attempt with Super-Glue worked. Last night I glued the Adjusting Bolt to the Sleeve, and let it set overnight. I made another attempt after I got back from work.

When the Piston Sleeve got up to the Circlip Groove, I screwed the Piston back onto the bolt, just before it started entering the bore. I used the Piston to get a better grip on the assembly, and the expletive-er finally popped out.

There is still a lot of gunk deep in the bore, so I'll be soaking it in Brake Fluid and rinsing with water for the next day or so. I'm 99% sure there is no Super Glue residue along the bore walls, but who knows...

Finally, both calipers are completely broken down. I'll post a write-up on the Exploded Caliper with OEM PNs and Pix, but I'm not sure if it would go best in this forum or in the Suspension Forum, and I don't want to get docked for double posting...

Anyway, if anyone else ever comes across this problem, Super-Glue works. (edit: Acetone will remove any Super-Glue residue)
JasonGhostz