Assembly - Caliper Piston And Seal

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Never use an old piston seal.

Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove. See Figureusing only your clean fingers to seat it.

Fig 1: Installing New Piston Seal
Courtesy of DAIMLERCHRYSLER CORP.

1 - CALIPER

2 - PISTON SEAL

3 - SEAL GROOVE
Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot.
Position the dust boot over the piston after coating it with brake fluid.
CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston.
Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. See Figure.

Fig 2: Installing Piston Into Caliper Bore
Courtesy of DAIMLERCHRYSLER CORP.

1 - BOOT

2 - PISTON

3 - CALIPER
Position the dust boot into the counterbore of the caliper assembly piston bore.

Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary. See Figure.

Fig 3: Installing Dust Boot

Courtesy of DAIMLERCHRYSLER CORP.

1 - HAMMER

2 - SPECIAL TOOL C-4171

3 - SPECIAL TOOL C-4689 or C-4842

4 - CALIPER

Reinstall the caliper on the vehicle and bleed the brakes as necessary. Refer to INSTALLATION - REAR DISC BRAKE CALIPER .