Twin Pot Brake Caliper Serviced With Repair Kit

After 2 month changed the brake rotor, it start to make sound again.
http://me2kimi.blogspot.com/2012/03/replacing-disc-and-brake-pad.html

So I've decided to service the caliper using repair kit. But unfortunately, I can't find brake repair kit for Levin twin pot caliper.

After been to few spare part shop, I've to buy 3 pack of brake repair kit. 2 sets of rear brake repair kit for Camry Acv30 and the other 1 is full set repair kit for Avanza. The Acv30 repair kit is compatible with twin pot size, but since twin pot caliper got 4 pistons in total, so I've to buy it 2 sets. Then I need to buy another full set of brake repair kit for just to use the slide pin boot as the boot did not sell separately.

Contain of the repair kit

First, took out the caliper and I need to push out the pistons from the caliper. I use portable tire pump to applied pressure into the caliper.

Before that, I've to wrap around the 'blue tip' using white tape or plumber tape to make sure it's air tight.

Then, put something at the other end of the piston to prevent it from pop out.

After that, slowly i can remove the piston from the caliper.

Lets see whats inside the caliper. It's full of rust and dirt. No wonder the brake is not working perfectly after I think 20 years of its age.

The caliper looks good after been clean, but not so good coz its aging already.

Then it's time to install the oil seal, dust cover and secure ring. When the oil seal is outside caliper, the diameter size is larger than size of the piston housing. But don't worry, once I put into the pistons housing, it will shrink and fit.

Now fit the dust cover and secure ring.

Before I put piston inside the caliper, I've lubricated it first with grease that come with Avanza repair kit.

Push piston down a into dust cover a bit (quite hard to fit into the dust cover) until touch the oil seal. 

Grab up end of the dust cover to fit to the piston.

And slowly push the piston inside the caliper.

When I tried to install slide pin boot into caliper bracket, it don't fit coz it got outer groove on it.

So I cut it out to be like this.

Then it fit inside the caliper bracket nicely.

AE111 twin pot replacing front disc and brake pad

In this thread I will show how I modified 5 hole disc to 4 hole and fit it into my AE111. Since my brother left his DC5 disc at my house, I will use his disc to fit into my car. This is tool that I use beside of the hand drill

Here is picture of original disc

Disc marked before drill

And here is 4 hole already drilled

To fit the disc into my car, firstly took out tyre and rim then took out caliper. Here is the picture in the process. Before started

By using this type of clamp, I push the brake pad further away so that easier when to install new disc

Remove this 2 screws that hold caliper

Then I hang the caliper to avoid caliper hanging only with brake hose

Test to fit modified disc rotor

Cheap brake pad that I used

New brake pad install

Then install back caliper into knuckle

Comparison before and after

Put wheel and ready to go. p/s:before that make sure continuously pump brake until feel brake pad grip before start driving