Been meaning to post this for awhile since I came across this a couple months ago now. So my entire brake system is not even 3 years old. I changed everything out when I got the truck, and half of all the slide pins were frozen to their brackets, and Napa would only sell me the brackets with the calipers. Last summer I changed all 5 brake hoses, and at least half the metal lines are new.

So about March one of my rear calipers starts locking up. This makes the 2nd time this has happened. I already warrantied a front caliper, and now my warranty is up. Made sense to at least take this one apart to see if I could figure it out.



These would stick after driving down the road about 10 minutes, and after sitting all day be ready to start the process over again. I had to use the brake pedal to get one out, and some pliers to finish getting the other out. They were very stuck.



Entire problem visible in this pic. The ring of rust right in front of the piston O-ring. You can also see one boot is torn in this pic but they are both rusty. And I think the boot tore while I was pressuring the piston out from inside lol.. dont know for sure.




My solution for now simply involves a dremel and grinding that ring down. It wont last long either I imagine. But it has been fine for 2 months now.

I dont know if this problem is limited to rebuilt calipers or what, but I could see how it could be... if they hone out those bores and dont put any protection on the outside.

So if you pick up any calipers you might just want to pull the piston and have a look in there. My plan for any new calipers is to spray some fluid film or likewise in the boot and hope for the best.