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Caliper - Front Twin 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 when assembling brake caliper.
NOTE: Never use old or used piston seals or boots for assembly.
Fig 1: Installing Piston Seals
GC0014376Courtesy of DAIMLERCHRYSLER CORP.
  1. Lubricate caliper pistons, piston seals (1) and piston bores (2) with clean, fresh brake fluid.
  2. Install NEW piston seal (1) into groove of each caliper piston bore (2).
    NOTE: Make sure seal is fully seated and not twisted in groove.
    Fig 2: Install Boot on Caliper Piston
    GC0014379Courtesy of DAIMLERCHRYSLER CORP.
  3. Install NEW boot (1) on each piston (2) and work boot lip into groove at top of piston. Stretch boot rearward straightening boot folds, then move boot forward as necessary until folds snap uniformly into place.
    Fig 3: Installing Pistons In Caliper
    GC0014375Courtesy of DAIMLERCHRYSLER CORP.
  4. Install each piston (1), one at a time, into its 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 is avoided.
    Fig 4: Measuring Dust Boot Heights
    GC0014378Courtesy of DAIMLERCHRYSLER CORP.
    CAUTION: When seating dust boots in following step, use care not to over-install boots or damage will occur. Each boot (2) will bottom in the counterbore before the top of the boot reaches the surface of the caliper. The boot will bottom with approximately 2 mm (1/16 inch) (3) of boot still showing above caliper housing.
    Fig 5: Seating Boots Using Tools 9315 and C-4171
    GC0014377Courtesy of DAIMLERCHRYSLER CORP.
  5. Seat dust boots (3) in caliper counterbores using Installer (2), Special Tool 9315, with Handle (1), Special Tool C-4171. Install each dust boot until it bottoms. Do not over-seat dust boot or damage will occur.
    Fig 6: Twin Piston Caliper Bleeder Screw
    GC0014374Courtesy of DAIMLERCHRYSLER CORP.
  6. Install caliper bleeder screw (2) in caliper housing (1). 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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