I just rebuilt one caliper yesterday. Seal set was $8 and took me maybe 2hours.

Jack up car, remove wheel. Removed brake pads and outer dust seals on rams and using some spanners as spacers and the brake pedal I extended the rams as far as I dared. They are about an inch long (!). Lubed them a bit to get them cleared.

Removed caliper and undid brake line (care full not to snap).

with caliper off the car I used compressed air to get the rams out (mind the fingers).

Cleaned the lot, changed ring seals in cylinder (rams are just metal barrels with no seals fitted). Cleaned the rams - surface was not pitted, but badly caked with muck.

Refit, bleed and presto, as working good.

When you extend the rams using the brake pedal you can probably already see the exend of the corrosion and wether it is worth while proceding. For a quick fix you can also just clean them and push them back at this point. My seals were not leaking so I could have done that, but preferred to have a good look inside instead.

regards,

Jorn
92 240 B200F M47 190kMiles