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Re: TR3 BRAKE DESPIRATION!!!!!!!!!!!

To: Geo Hahn <ahwahnee@cybertrails.com>
Subject: Re: TR3 BRAKE DESPIRATION!!!!!!!!!!!
From: Don Malling <dmallin@attglobal.net>
Date: Tue, 15 Nov 2005 15:19:25 -0500
Geo Hahn wrote:
> Peter Ryner wrote:
> 
>> I can't remember the exact design of the TR3 dust boot, but I believe you
>> have to install it in the bore before installing the piston.  It fits 
>> in a
>> groove at the top of the bore and can't be installed after the piston is
>> installed.
>>
> 
> Correct.  I get everything poised for assembly (with a piston 
> temporarily in the opposite side for the first one) block of wood 
> between the 2 pistons and the piston to be inserted sitting on top of 
> the dust boot.  Apply mild air pressure to the hose hole and the boot 
> will inflate and almost want to go around the piston.  All it needs then 
> is a little help... I use a length of 12g solid copper wire bent into a 
> hook with the end rounded smooth.
> 
> Some brake-approved lube (aka red snot) helps it go together.
> 
> First one takes about a minute, by the time you do the fourth it will 
> pop on in 2 seconds.  Helps to have someone else manning the air pressure.
> 
> Geo Hahn
> 
> 
> 

I followed Geo's instuctions when doing my TR250 calipers. I believe the boots 
are the same. You 
must install the boot before the piston goes in. The problem is that when you 
then put the piston 
in, the boot lip folds under, is pointed downward towards the caliper cavity, 
and binds with the 
piston going into the caliper cavity. I think, as Geo says, an air compressor 
would help by 
inflating the boot and forcing it to not be folded under. I didn't have a air 
compressor handy, but 
I did use Geo's suggestion of a 12g solid copper wire with a hook on the end. 
You can get the hook 
under the folded down boot lip and lift it outward it so it points away from 
the caliper cavity. It 
will then slide along the piston very nicely as you push the piston into the 
caliper cavity. As you 
push the piston in, the boot lip slips right into the piston groove. Don't 
forget to round off any 
sharp edges on the wire so it doesn't damage the boot. I also had everything 
coated with the red 
rubber lube stuff.

I did this one caliper half at a time.

My pistons were a hard push. Once in, I had real problems getting them out.

Thanks Geo -- you're a life saver.

Don Malling


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