I was replacing the last of 4 new pads (front right inner pad) and compressed the lower piston. The upper piston popped out and will not go back in! I tried a c-clamp and taking off the cap on the reservoir but this didn't work. The seal is not torn or leaking but it looks like it is stretched to its maximum. Is there some reataining ring or something that may have popped out or slipped? I really don't want to have my car towed to the brake shop for something so silly, but it's looking like I have no other option. The piston is really stuck! It won't budge even a little, and it broke the little nub on the c-clamp.

Coincidentally, the inner-front pad was the most worn out of all of them. The rest of the pads looked to have maybe 3-5K miles left on them, but this one was almost to the backing plate.

 

I believe if you open up the bleed nipple you will be able to press it back in, but you will have to bleed your brakes after doing so as air will likely get in the lines. I can't think of another way to do it.

-Paul

 

The "pop-out" you're describing I haven't heard before on an EVO, but my guess is that the piston is misaligned, or you just don't have enough ooomph to get it back in (once they're out, they can be a real ***** to get back in - the fit is ULTRA tight).

The inner pad wear I have noticed before.

Note the severely worn pad is the right front inner pad (all others with remaining material)



Shawn

 

you get this figured out yet? i am curious to know how you fixed it.

 

Thanks for the input, problem solved. I was using too small of a C-clamp which was only pushing on one side of the piston, so it was just trying to go in cockeyed. I went to Sears & bought a 5" C-clamp, removed the 2 attachment bolts from the caliper to take it off & maneuver it to where I could get at it, and it went in almost effortlessly. I feel like a dumbass lol. And to think, I used to be a helicopter mechanic!

 

Everybody makes mistakes. So, it was just misaligned. Good. Happy braking.

Shawn