Brake Caliper rebuild kit - Rascal, Super Carry, Nipper, Bambi etc..

This is a brake caliper rebuild kit for BOTH SIDES for the Bedford/Vauxhall Rascal, bambi, nipper, danbury , super carry etc... 

Provided your caliper is complete and the groove for the main piston seal is undamaged and not badly pitted, then this is all you need to restore a brake caliper to new.

You need to strip down the caliper, remove all seals and the piston, clean it up using abrasive methods such as a wire brush or use chemical methods such as a suitable acid bath, or a good ultrasonic cleaner with appropriate fluid.

The key thing is not to damage the main piston seal grove, this is what does ALL the work and will likely leak if  damaged or prevent the piston moving if not cleaned out properly.

Removing the old piston, especially if seized can be tricky, if possible use the brake pedal when it is still fitted if the piston moves, in order to push it out. keep fingers out of the way!, else you can use an air line into the banjo bolt hole.. or if you place the caliper in a vice, you can carefully use the smooth end of a large drill bit slid through the banjo bolt hole onto the piston inside, then use a hammer to hit the piston and knock it out bit by bit.

if it still refuses to move, pour some penetrating fluid into that hole first and leave soak, if still no go then a blow torch applied into the piston bowl to heat it up nice and hot should break and remaining rust bond, then knock it out.

once stripped and cleaned (the sliders and piston bore are key, the rest is cosmetic), fit the new piston seal into its groove, wipe a smidge of silicone grease onto it, fit the dust boot, the groove for this you will discover needs to be clean as it is a difficult enough task to fit it as it is. a little silicone grease helps here.

apply a smear of silicone grease to the piston outer.

Fitting the piston back in involves getting the dust shield over the piston, this we find is easiest if you have compressed air available, even a tyre pump will help, blow it into the banjo hole while pushing the piston against the boot, it may take a few tries but once the boot is over the piston, you can push it in.

The sliders need greasing and the new boots fitted, again the groves they sit in to hold them in place need to be clean.

Now wipe of any external silicone and get it off your hands (you were wearing gloves, right? :) ) before fitting the pads and pad retainers.