P38A Front Brake Piston Hell

As the title suggests, i am having a nightmare refitting the front brake caliper pistons back in without trashing the new seals.
I have refurbed the lot and need to ask if any one has a idiot proof way of getting the pistons back in, straight, with only a large engineers vice, some red grease and a half drunk bottle of Merlot...(which will help with my internet research into this subject and then probably some porn research)

I have done many 'Normal' cars and motorcycles but these seem to be cursed.
What method has worked for you ?? on the brakes, not porn.

Split the callipers, fit seals, fit pistons, bolt callipers back together.
I've done quite a few.

dont think lubricating the seals with Merlot is a good idea

You may be onto something there, maybe I need to use more lubrication....

'The wetter the better' applies to many things.

Did you use the Britpart kit? Heard horror stories on them, especially the sealing ring.

Warm the caliper with an heat gun freeze the piston. Plenty of brake grease.

wammers said:

Warm the caliper with an heat gun freeze the piston. Plenty of brake grease.

Click to expand...

Brake grease. That's the red stuff?

I just push them in with my thumbs?
Fit inner seal then lubed piston ( just brake fluid) then wiper seal/ metal ring pre assembled over the piston, tapped home with a suitable piece of tube.
Britpart kits- no problem.

Grrrrrr said:

Brake grease. That's the red stuff?

Click to expand...

Yes.

Bloody things, getting the polished and lubed piston past the bottom fluid seal is not a problem..
Fitting the top dust seal into the caliper groove 1st, fitting the piston shears it off,
Fitting dust seal into piston groove first, then can't get to the caliper groove to press in seal without damaging it.
Am I missing a special, expensive p38 tool. Seals never been this crappy to do before.
Any pointers before I fire up the propane melting pot.

Enuff said:

Bloody things, getting the polished and lubed piston past the bottom fluid seal is not a problem..
Fitting the top dust seal into the caliper groove 1st, fitting the piston shears it off,
Fitting dust seal into piston groove first, then can't get to the caliper groove to press in seal without damaging it.
Am I missing a special, expensive p38 tool. Seals never been this crappy to do before.
Any pointers before I fire up the propane melting pot.

Click to expand...

Is Flossie nearby?!

'ang on, I may be talking nuts...just realised you're talking p38, I was thinking Defenders- sorry. I've no idea what the seals are like on them.
However...see if you can source the inner seals , assuming the callipers split, and just split them.
Put a pic up?

You know that warm feeling of satisfaction when you achieve whatever goal your aiming for..
I had it briefly with a moment of realisation that fitting new seals and sliding the piston with ease into the caliper, can be done in about 15 seconds each.
Well done to land rover, they put a bit of thought into the brakes on the p38.
Couldn't find anything on rave, but there's 3 seals per piston, fit bottom one, only half fit top one, fit middle one, ease piston in, top one plops into place. Logical.
Easy when you know how. Oh and thanks for sharing......yes you.

Thanks for input Flossie...yes they are a bit different to other brakes have done.
No hammering metal rimmed seals in or using a press.

Enuff said:

You know that warm feeling of satisfaction when you achieve whatever goal your aiming for..
I had it briefly with a moment of realisation that fitting new seals and sliding the piston with ease into the caliper, can be done in about 15 seconds each.
Well done to land rover, they put a bit of thought into the brakes on the p38.
Couldn't find anything on rave, but there's 3 seals per piston, fit bottom one, only half fit top one, fit middle one, ease piston in, top one plops into place. Logical.
Easy when you know how. Oh and thanks for sharing......yes you.

Click to expand...

That's a bl**dy good tip. I've still got my old ones in the shed awaiting refurbishment.