u/Ilitihr

Need help: Shimano XT brake blocked after oil leak and piston over-extension

Hello everyone,

I need some help setting up my hydraulic Shimano XT brake (2-piston system). My current problem is that I cannot get the wheel (with the brake rotor) back into the frame/fork because the brake pads are sitting too close together.

How it happened: My brake was rubbing slightly, and I wanted to adjust it. Unfortunately, I accidentally loosened the wrong bolts on the brake caliper. As a result, a large amount of mineral oil leaked out, and I suspect some of it might have contaminated the brake pads (though I'm not entirely sure).

Afterward, I refilled the system with mineral oil because the bite point was completely gone. While refilling/testing, I pulled the brake lever as a test—however, the wheel was out at that moment. It seems the brake pistons extended way too far and are now stuck in that position.

My questions for you:

  1. Can I safely push the brake pistons back into the caliper? What is the best tool to use for this without causing any damage? (The pads are currently still inside).
  2. Since this is my very first time repairing anything on my bike: Is there anything important I might have missed, or are there steps (e.g., proper bleeding or replacing the pads) that I absolutely need to do now?

Thanks a lot for your help!

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u/Ilitihr — 3 days ago