How to rebuild Brembo brake calipers

Kit Contents

If you purchase the piston kit, you will receive the correct number of pistons, silicone dust boots, oil seals, and stainless steel bleeding screws (note: not available for some models).

If you purchase the silicone dust boot upgrade kit, you will receive the correct number of silicone dust boots, oil seals, and stainless steel bleeding screws (note: not available for some models).

All kits include a sufficient amount of rubber grease for installation.

Recommended Tools

While the process of removing brake calipers from the car will vary depending on the vehicle, here are several helpful tools that can make the rebuild process safer and easier:

• A 50-70 cm stick to press the brake pedal and hold pressure on the system.

• An 11 mm wrench, useful for operating the bleeding screw.

• A rubber block or piece of wood to place between pistons, preventing them from ejecting forcefully when air pressure is applied.

• A narrow flathead screwdriver, thin enough to assist with removing or seating oil seals and dust boots.

Before remove caliper

After lifting your vehicle, you can use the long stick to press the brake pedal down about 2–5 cm. This will help reduce the amount of brake fluid that leaks out when the brake line is disconnected.

However, please note that once the line is under pressure, fluid may spray out suddenly when the banjo bolt or screw is released. For safety, we recommend first using a bleeding tool to release pressure from the brake system before loosening any fittings.

We recommend keeping your car key at least 10 meters away from the vehicle. Some cars become not happy when their computer detects that the brake system cannot build pressure. 

Removing Pistons and Seals

After removing the caliper and brake pads, place a rubber block or wooden piece in the center of the caliper. Use compressed air to push the pistons out.

Warning: Never place your fingers in the path of a moving piston. The force of the piston can cause serious injury or even bone fractures.

Once the pistons are removed, use a narrow flathead screwdriver to carefully take out the dust boots and oil seals. Be careful not to damage the caliper body.

After disassembly, clean the caliper with a neutral cleaner. Do not use acidic or alkaline cleaners, as these can corrode the caliper's plating or anodized surface finish.

Chemical Safety Notice

Do not allow alcohol-based or solvent-based cleaners to come into prolonged contact with any silicone or rubber components. Common products such as WURTH Ultra 2040 or typical brake cleaners can cause damage and premature failure of dust boots, oil seals, and other rubber parts. Always use a neutral cleaner and rinse thoroughly with clean water.

Installing New Oil Seals and Dust Boots

Lightly coat the new oil seals with the supplied rubber grease, then press them evenly into the caliper grooves. Make sure they are seated fully without twisting.

Apply a thin layer of grease to the piston surface before installation.

Important: Do not apply grease to the silicone dust boots. Grease will cause the boots to slip out of their grooves and lose their sealing function.

The dust boots must be pressed firmly into the caliper groove until they seat securely. When the dust boot is mounted onto the piston, it should look exactly like the photos provided. Each BCB dust boot is designed with a small vent hole located under the letter "C" in the BCB logo. This vent allows trapped air to escape from inside the boot during operation, preventing pressure build-up.

Carefully push the piston straight into the caliper until it is fully seated. Then press the dust boot into the groove on the caliper body to complete the seal.

Double-check that all seals and boots are properly seated before moving to the next piston.

Installing Bleeding Screws

When installing the bleeding screws, do not overtighten in order to align the logo or any markings, and do not leave them under-tightened.

Always tighten the screws with proper force. If you need a specific reference, the recommended torque is approximately 18–24 Nm.

Final Assembly and Bleeding

Reinstall the calipers and brake pads onto the vehicle. If you have installed high top pistons, check that the brake pad thickness matches the original specification. If there is a difference, inspect for any shims that may need to be removed. In most cases, this will not be an issue.

After reassembly, bleed the brake system following the procedure specified in your vehicle's service manual. Once bleeding is complete, flush the inside of each bleeding screw with clean water and compressed air to remove any residual brake fluid. This will prevent brake fluid from seeping out at high temperature and damaging the paint.

Next, reinstall the wheels and tighten them to the specified torque as outlined in your service manual.

Important: For best results, we recommend driving the vehicle in a safe area after the first bleeding, then performing a second round of bleeding to ensure there is no air remaining in the brake lines. Always remove the wheels for this procedure—do not attempt to loosen or tighten bleeding screws with the wheels installed just to save time.