ZCP rear caliper rebuild problems...

ZCP M3 · Fri, Jul-25-2008, 05:55:29 PM

Hey all,
I melted off my dust boots from track use so I figured I'd go ahead and rebuild them. The front's went without a hitch, but these rear ZCP dust boots are a serious PITA. They have a metal ring embedded into the rubber seal that snaps over the top of the piston bore, instead of sitting inside like every other caliper seal ever created. I cannot for the life of me get these things in place and have torn through two sets already.

The BMW dealership I took it to ordered the stock M3 ones instead of the ZCP's like i instructed them and are now at a loss as far as what to do and from the conversation we had they may have thrown away the old internal seals, making the car currently undriveable.

Anyone have a trick to getting these things on?

mmmpowr · Fri, Jul-25-2008, 06:12:56 PM

Quote:

Originally Posted by ZCP M3

Hey all,
I melted off my dust boots from track use so I figured I'd go ahead and rebuild them. The front's went without a hitch, but these rear ZCP dust boots are a serious PITA. They have a metal ring embedded into the rubber seal that snaps over the top of the piston bore, instead of sitting inside like every other caliper seal ever created. I cannot for the life of me get these things in place and have torn through two sets already.

The BMW dealership I took it to ordered the stock M3 ones instead of the ZCP's like i instructed them and are now at a loss as far as what to do and from the conversation we had they may have thrown away the old internal seals, making the car currently undriveable.

Anyone have a trick to getting these things on?

How about some pictures of what all the pieces look like, that would help.

ZCP M3 · Fri, Jul-25-2008, 06:15:34 PM

I wish I had pictures. Can't take any because the car is sitting at the dealership while they look for the old internal seals to put the calipers back together and get the car running again.

mmmpowr · Fri, Jul-25-2008, 06:28:07 PM

See if this helps: http://www.pelicanparts.com/bmw/tech...er-Rebuild.htm

ZCP M3 · Fri, Jul-25-2008, 06:31:52 PM

Thats the key difference between the regular M3 and the ZCP's rear calipers. Instead of the dust boot fitting into a recess in the piston bore, there is a metal ring that sits on a bevel on the OUTSIDE of the piston bore. That's what's impossible to get on. I did the front calipers (pictured) without a hitch.

mmmpowr · Fri, Jul-25-2008, 06:42:58 PM

Quote:

Originally Posted by ZCP M3

Thats the key difference between the regular M3 and the ZCP's rear calipers. Instead of the dust boot fitting into a recess in the piston bore, there is a metal ring that sits on a bevel on the OUTSIDE of the piston bore. That's what's impossible to get on. I did the front calipers (pictured) without a hitch.

This DIY shows a metal ring: http://bmwe32.masscom.net/sean750/ca...akeCaliper.htm

ZCP M3 · Fri, Jul-25-2008, 06:46:33 PM

The following image is what I'm talking about...

This shows the dust boot being secured to the caliper by a lip inside a recess in the piston bore. Again, the ZCP rears DO NOT have this. They have an embedded metal ring that fits over the outside of the piston bore. Not like the above where they have a snap ring either.

ZCP M3 · Fri, Jul-25-2008, 06:49:10 PM

The ZCP rears are like this, but instead of snapping a metal ring around the rubber boot to keep it in place, it is embedded in the rubber boot, making things SIGNIFICANTLY more difficult.

Anyone with a ZCP care to chime in?

mmmpowr · Fri, Jul-25-2008, 07:06:30 PM

have you lubbed it with brake fluid or PBR Rubber Grease (http://www.hrpworld.com/index.cfm?fo...action=product) to help get it on?

ZCP M3 · Fri, Jul-25-2008, 07:32:31 PM

Used plenty of brake fluid to lube everything up, no help.

Fri, Jul-25-2008, 05:55:29 PM	#1
ZCP M3 Track ***** Join Date: Jan 2006 Posts: 1,107 Reputation: 0 Location: St. Louis, MO	ZCP rear caliper rebuild problems... Hey all, I melted off my dust boots from track use so I figured I'd go ahead and rebuild them. The front's went without a hitch, but these rear ZCP dust boots are a serious PITA. They have a metal ring embedded into the rubber seal that snaps over the top of the piston bore, instead of sitting inside like every other caliper seal ever created. I cannot for the life of me get these things in place and have torn through two sets already. The BMW dealership I took it to ordered the stock M3 ones instead of the ZCP's like i instructed them and are now at a loss as far as what to do and from the conversation we had they may have thrown away the old internal seals, making the car currently undriveable. Anyone have a trick to getting these things on? __________________ Zach 2006 E46 ///M3 Coupe \| 6 speed manual \| ZCP Competition Package \| Interlagos Blue on Gray Go fast mods: Hardwired Valentine V1 \| CDV Delete Appearance mods: Smoked Corner Lights \| Silverstar Turn Signal Bulbs \| Painted Corner Reflectors \| Painted Shadow Kidney Grilles \| Fucy CF Side Grilles \| PIAA Yellow HID Foglight Bulbs \| Tungsten Silver ZCP Wheels

Fri, Jul-25-2008, 06:15:34 PM	#3
ZCP M3 Track ***** Join Date: Jan 2006 Posts: 1,107 Reputation: 0 Location: St. Louis, MO	I wish I had pictures. Can't take any because the car is sitting at the dealership while they look for the old internal seals to put the calipers back together and get the car running again. __________________ Zach 2006 E46 ///M3 Coupe \| 6 speed manual \| ZCP Competition Package \| Interlagos Blue on Gray Go fast mods: Hardwired Valentine V1 \| CDV Delete Appearance mods: Smoked Corner Lights \| Silverstar Turn Signal Bulbs \| Painted Corner Reflectors \| Painted Shadow Kidney Grilles \| Fucy CF Side Grilles \| PIAA Yellow HID Foglight Bulbs \| Tungsten Silver ZCP Wheels

Fri, Jul-25-2008, 06:28:07 PM	#4
mmmpowr Registered User Join Date: Oct 2004 Posts: 905 Reputation: 0 Location: Farmington Hills, MI	See if this helps: http://www.pelicanparts.com/bmw/tech...er-Rebuild.htm __________________ David 2001 ///M3 OEM: 6-Speed \| Titanium Silver Metallic \| Imola Nappa Leather \| Power Seat Package \| Cold Weather Package \| Width adj. front seat with lumbar \| Xenon \| Moonroof \| In-dash CD \| HK \| BMW alarm \| Univeral transceiver Mods: OEM Strut brace \| OEM 19" wheels (street) \| RAC RS110 9.5"(f)/10"(r) wheels (track) \| Brembo 355(f)/345(r) BBK \| Motul RBF600brake fluid \| ACS rear shock tower brace \| D/A Race software \| SS Stepped Headers/S-pipe/X-pipe w/resonator/Race muffler \| RE pullies \| aFe CAI stg1 \| Bimmerworld intake elbow \| Bimmerworld CF brake ducts \| BMW Motorsport thermostat \| TCK D/A coilovers w/#600(f)/#700(r) \| GC camber/castor Race plate \| Powerflex FCAB \| GC front sway bar links \| h-Sport sway bars \| RE Tranny mounts \| TCK RTAB \| GC RLCA\| TCK shock mounts \| V-CSL CF trunk \| V-CSL CF diffuser \| McMahan 4pt rollbar \| TMS oil cooler \| RE Octane SSK

Fri, Jul-25-2008, 06:31:52 PM	#5
ZCP M3 Track ***** Join Date: Jan 2006 Posts: 1,107 Reputation: 0 Location: St. Louis, MO	Thats the key difference between the regular M3 and the ZCP's rear calipers. Instead of the dust boot fitting into a recess in the piston bore, there is a metal ring that sits on a bevel on the OUTSIDE of the piston bore. That's what's impossible to get on. I did the front calipers (pictured) without a hitch. __________________ Zach 2006 E46 ///M3 Coupe \| 6 speed manual \| ZCP Competition Package \| Interlagos Blue on Gray Go fast mods: Hardwired Valentine V1 \| CDV Delete Appearance mods: Smoked Corner Lights \| Silverstar Turn Signal Bulbs \| Painted Corner Reflectors \| Painted Shadow Kidney Grilles \| Fucy CF Side Grilles \| PIAA Yellow HID Foglight Bulbs \| Tungsten Silver ZCP Wheels

Fri, Jul-25-2008, 06:46:33 PM	#7
ZCP M3 Track ***** Join Date: Jan 2006 Posts: 1,107 Reputation: 0 Location: St. Louis, MO	The following image is what I'm talking about... This shows the dust boot being secured to the caliper by a lip inside a recess in the piston bore. Again, the ZCP rears DO NOT have this. They have an embedded metal ring that fits over the outside of the piston bore. Not like the above where they have a snap ring either. __________________ Zach 2006 E46 ///M3 Coupe \| 6 speed manual \| ZCP Competition Package \| Interlagos Blue on Gray Go fast mods: Hardwired Valentine V1 \| CDV Delete Appearance mods: Smoked Corner Lights \| Silverstar Turn Signal Bulbs \| Painted Corner Reflectors \| Painted Shadow Kidney Grilles \| Fucy CF Side Grilles \| PIAA Yellow HID Foglight Bulbs \| Tungsten Silver ZCP Wheels

Fri, Jul-25-2008, 06:49:10 PM	#8
ZCP M3 Track ***** Join Date: Jan 2006 Posts: 1,107 Reputation: 0 Location: St. Louis, MO	The ZCP rears are like this, but instead of snapping a metal ring around the rubber boot to keep it in place, it is embedded in the rubber boot, making things SIGNIFICANTLY more difficult. Anyone with a ZCP care to chime in? __________________ Zach 2006 E46 ///M3 Coupe \| 6 speed manual \| ZCP Competition Package \| Interlagos Blue on Gray Go fast mods: Hardwired Valentine V1 \| CDV Delete Appearance mods: Smoked Corner Lights \| Silverstar Turn Signal Bulbs \| Painted Corner Reflectors \| Painted Shadow Kidney Grilles \| Fucy CF Side Grilles \| PIAA Yellow HID Foglight Bulbs \| Tungsten Silver ZCP Wheels

Fri, Jul-25-2008, 07:06:30 PM	#9
mmmpowr Registered User Join Date: Oct 2004 Posts: 905 Reputation: 0 Location: Farmington Hills, MI	have you lubbed it with brake fluid or PBR Rubber Grease (http://www.hrpworld.com/index.cfm?fo...action=product) to help get it on? __________________ David 2001 ///M3 OEM: 6-Speed \| Titanium Silver Metallic \| Imola Nappa Leather \| Power Seat Package \| Cold Weather Package \| Width adj. front seat with lumbar \| Xenon \| Moonroof \| In-dash CD \| HK \| BMW alarm \| Univeral transceiver Mods: OEM Strut brace \| OEM 19" wheels (street) \| RAC RS110 9.5"(f)/10"(r) wheels (track) \| Brembo 355(f)/345(r) BBK \| Motul RBF600brake fluid \| ACS rear shock tower brace \| D/A Race software \| SS Stepped Headers/S-pipe/X-pipe w/resonator/Race muffler \| RE pullies \| aFe CAI stg1 \| Bimmerworld intake elbow \| Bimmerworld CF brake ducts \| BMW Motorsport thermostat \| TCK D/A coilovers w/#600(f)/#700(r) \| GC camber/castor Race plate \| Powerflex FCAB \| GC front sway bar links \| h-Sport sway bars \| RE Tranny mounts \| TCK RTAB \| GC RLCA\| TCK shock mounts \| V-CSL CF trunk \| V-CSL CF diffuser \| McMahan 4pt rollbar \| TMS oil cooler \| RE Octane SSK

Fri, Jul-25-2008, 07:32:31 PM	#10
ZCP M3 Track ***** Join Date: Jan 2006 Posts: 1,107 Reputation: 0 Location: St. Louis, MO	Used plenty of brake fluid to lube everything up, no help. __________________ Zach 2006 E46 ///M3 Coupe \| 6 speed manual \| ZCP Competition Package \| Interlagos Blue on Gray Go fast mods: Hardwired Valentine V1 \| CDV Delete Appearance mods: Smoked Corner Lights \| Silverstar Turn Signal Bulbs \| Painted Corner Reflectors \| Painted Shadow Kidney Grilles \| Fucy CF Side Grilles \| PIAA Yellow HID Foglight Bulbs \| Tungsten Silver ZCP Wheels

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