Caliper-Front Disc Brake: Assembly

NOTE: Always have clean hands when assembling a brake caliper.

NOTE: Always use fresh, clean brake fluid when assembling a brake caliper.

Fig 1: New Piston Seal Installation

Courtesy of DAIMLERCHRYSLER CORP.

1 - SEAL

2 - GROOVE

NOTE: Never use an old piston seal.

Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only your clean fingers to seat it.

Fig 2: Boot Installation
Courtesy of DAIMLERCHRYSLER CORP.
Coat the NEW piston with clean brake fluid.
Coat the NEW piston boot with clean brake fluid leaving a generous amount inside the boot.
Position the dust boot over the lower section of the piston.
Extend the dust boot below the bottom of the piston and guide the lip seal into the groove in the caliper piston bore.

Fig 3: Piston Installation
Courtesy of DAIMLERCHRYSLER CORP.

1 - PISTON GROOVE

CAUTION: Force applied to the piston (1) to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston.
Install the piston (1) into the bore, carefully pushing it past the piston seal using hand pressure . Push the piston in until it bottoms in the caliper bore and the dust boot lip seal falls into the groove near the top of the piston.
Install the caliper on the vehicle and bleed the brakes as necessary. (Refer to BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER - INSTALLATION)