I’m just fitting new discs and pads to the rear and one of the dust seals has split, do I need to remove the piston to replace, I’m hoping to avoid have to re bleed the system. It’s a 2011 Mini Cooper R57
Probably, most of them do in my experience. The problem is, you don't know how long it has been split for and how much water has got into the calliper, I'd be replacing it because it will be on borrowed time now before it seizes.