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Gilrling caliper rebuild problems 140-160

posted by  marmiteman on  Sat May 8 07:29 CST 2021
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Hello All. I am in the process of redoing all the brakes on my 74 145. It was sitting for close to thirty years so the Girling calipers are well overdue a rebuild.

But after a couple of days of head scratching I am still stuck. I have managed to get the pistons to move in their bores, but I cannot work out how to get both pistons out of the caliper. Of course I can get one out, but then I cannot build any pressure for the other. And, if I push two opposing pistons out, they touch in the middle of travel and neither will release.

In the green book, it is suggested that I release one piston then cover the hole with a rubber washer and tool 2809 to build enough pressure to release the other. I don't have the tool but have rigged something equivalent and no dice.

This whole thing is reminding me of those infuriating puzzles that my Uncle Jim used to bring to Christmas dinner. Seems like there is a simple solution but I can't work it out.

Please put me out of my misery.

Any help or guidance most appreciated. Warren








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    Gilrling caliper rebuild problems 140-160

    posted by  Ron Kwas on  Sat May 8 17:25 CST 2021
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    last visit: Fri Oct 24 04:03 CST 2014
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    Warren;

    The trick is to get all the pistons moving (shop air is often enough) and to the center, using strategically sized and placed wooden blocks, as far as possible...the first piston to pop out means you're done using pressure on that system...after that its mechanical extraction with a channel lock pliers, or with a flat blade screwdriver in the dustboot slot...

    Good Hunting!








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      Gilrling caliper rebuild problems 140-160

      posted by  marmiteman on  Sun May 9 15:32 CST 2021
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      Thanks for the suggestion, and thanks to Dave too. I was reluctant to go the "one half at a time" route because of the possibility of dirtying the clean half with crud from the dirty half. I managed to get all the pistons out with the strategically placed piece of wood (note to self: remember to leave enough overhang to be able to pull the wood from between the pistons when they are gripping it). It was the channel locks and a vice grip that saved the day. A lot of wiggling and some patience and...job done.

      Thank you Ron and thank you Brickboard.

      Warren








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    Gilrling caliper rebuild problems 140-160

    posted by  Volvo From Heck on  Sat May 8 08:41 CST 2021
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    last visit: Mon Oct 13 20:56 CST 2014
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    Is the problem that your homemade "plug" isn't working as well as you want? If that's the case you can clean the bore of the one that's out--re-install that piston and use opened up hose clamps to then contain those remaining pistons except for the next one to get removed. If the pistons are frozen in a partially extended position use a "C" clamp to force it/them back first. Watch where you place your fingers--air pressure can launch the piston out like a rocket. - Dave








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      Gilrling caliper rebuild problems 140-160

      posted by  marmiteman on  Sat May 8 10:45 CST 2021
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      thanks for the reply. so, essentially, are you saying do one half at a time? pop one side out, clean, install new seal and reinstall piston and hold in place while releasing the other side and repeating?








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        Gilrling caliper rebuild problems 140-160

        posted by  Volvo From Heck on  Sat May 8 11:36 CST 2021
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        last visit: Mon Oct 13 20:56 CST 2014
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        Yes, and you do realize the front calipers have 2 pistons on each half--4 all together. The rears have 1 inner, 1 outer for each caliper. Do the fronts 1/4 at a time by restraining the remaining pistons. -- Dave







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