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Rear Brake Calipers - Wit's End! 200 1987

I feel your frustration, as I've been there with a master cylinder from Autozone.

If you're pretty sure you aren't going to return one of them for warranty replacement or refund (or maybe even if you do) I would go ahead and take the dust seals off and blow the pistons out of the bores, being careful to cushion their exit with some soft wood, cardboard, or something softer than the pistons themselves. Check out the piston surfaces for pits, rust, etc. It would be interesting to see if they even put new pistons in. Anyway, chances are they didn't clean up the bores adequately. "Surely" they at least put new seals in. Carefully remove the seal with a tiny dental pick (Harbor Freight) and clean up the bores with some 600-800 grit sand paper. Make sure you sand them in a circular motion around the bore rather than just sanding in and out. Without any seal in the bore, make sure the piston slides freely in and out. Flush out the caliper with something like carb cleaner and blow out all the passages with air. If you get the seal good and wet with brake fluid it is easier to work back into the groove. Put the pistons back in and the dust boost on. What have you got to lose? Heck, if it still doesn't work right, take it back to the store. You won't have screwed it up any worse than THEY did.
--
Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (getting ever closer to road worthiness)






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