Piston And Seal

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

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

Fig 1: Rear Caliper Piston Seal Installation

Courtesy of DAIMLERCHRYSLER CORP.

CAUTION: 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 and into the groove using only finger pressure to seat it.

Fig 2: Install Boot on Caliper Piston
Courtesy of DAIMLERCHRYSLER CORP.
Coat the inside of the NEW piston dust boot with clean brake fluid.
Install the dust boot (1) over the piston (2) and into the groove at the top of the piston. Stretch the boot downward, straightening the folds, then move it back upward. Repeat as necessary until the all the folds snap uniformly into place.

Fig 3: INSTALL PISTON INTO CALIPER
Courtesy of DAIMLERCHRYSLER CORP.

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 the piston (1) into the caliper (2) by pushing it past the piston seal until it bottoms in the caliper bore.

Fig 4: INSTALLING DUST BOOT IN CALIPER
Courtesy of DAIMLERCHRYSLER CORP.
Position the dust boot in the top of the counterbore of the caliper piston bore.
Using a hammer with Installer (2), Special Tool C-4689, and Handle (1), Special Tool C-4171, drive the boot into the counterbore of the caliper (3).
Install the caliper on the vehicle and bleed the brakes as necessary. (Refer to BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER - INSTALLATION)