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Caliper - Front Single Piston Disc Brake: Assembly

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Dirt, oil, and solvents can damage caliper seals. Ensure assembly area is clean and dry.
NOTE: Always use new, clean Mopar® DOT 3 Motor Vehicle Brake Fluid or equivalent when assembling brake caliper.
NOTE: Never use used or old piston seals or boots for reassembly.
Fig 1: Rear Caliper Piston Seal Installation
GC0014362Courtesy of DAIMLERCHRYSLER CORP.
  1. Lubricate caliper piston, piston seal (1) and piston bore (2) with clean, fresh brake fluid.
  2. Install NEW piston seal (1) in groove of caliper bore (2). Seal should be started at one area of groove and gently worked around and into the groove using only your clean fingers to seat it.
    Fig 2: Installing Boot on Piston
    GC0014364Courtesy of DAIMLERCHRYSLER CORP.
  3. Install NEW dust boot (1) on piston (2) and work boot lip into groove at top of piston. Stretch boot downward, straightening boot folds, then move boot back upward as necessary until folds snap uniformly into place.
    Fig 3: Install Piston In Rear Caliper
    GC0014363Courtesy of DAIMLERCHRYSLER CORP.
  4. Install piston (1) into caliper piston (2) bore, pressing piston down to bottom of bore using hand-pressure. Using a piece of wood or wooden hammer handle may also suffice as long as piston and boot damage can be avoided. The dust boot will not seat at this time. Refer to following step. 
    Fig 4: Install Dust Boot Using Tool 9315 and C-4171
    GC0014365Courtesy of DAIMLERCHRYSLER CORP.
  5. Seat dust boot (3) in caliper counterbore using Installer (2), Special Tool 9315, with Handle (1), Special Tool C-4171. Install dust boot until it bottoms. Do not over-seat dust boot or damage will occur.
    Fig 5: Rear Caliper Bleeder Screw
    GC0014361Courtesy of DAIMLERCHRYSLER CORP.
  6. Install bleeder screw in correct threaded hole. Caliper housing is not side-specific, so it is important to install bleeder screw in threaded hole that will be uppermost once caliper is installed on vehicle. Tighten bleeder screw to 15 N.m (125 in. lbs.) torque.
  7. Install caliper on vehicle. (Refer to BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER - INSTALLATION) 
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