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Caliper, Disc Brake, Rear: Assembly: Assembly

WARNING: This page is about a different car, the 2013 Dodge Avenger and 2013 Chrysler 200. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

Always have clean hands when assembling a brake caliper.

NOTE:

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

Fig 1: Seal Installation
GC0083925Courtesy of CHRYSLER GROUP, LLC
NOTE:

Never use an old piston seal.

  1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper piston bore. The seal (1) should be started at one area of the groove and gently worked around into the groove using only clean finger tips to seat it.
    Fig 2: Snap Ring Groove Positioned Upward
    GC0083926Courtesy of CHRYSLER GROUP, LLC
  2. Coat the NEW piston dust boot (1) with clean brake fluid leaving a generous amount inside the boot.
  3. Position the dust boot over the top of the piston (2) and into the piston groove. Make sure the side of the dust boot with the outer lip (3) for the boot snap-ring is positioned upward as shown in illustration.
  4. Coat the piston with clean brake fluid.
    Fig 3: Piston Installation
    GC0083927Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston.

  5. Insert the piston into the caliper bore, carefully pushing it past the piston seal using hand pressure  . Push the piston in until it bottoms in the caliper bore.
    Fig 4: Installing Boot In Groove
    GC0083928Courtesy of CHRYSLER GROUP, LLC
  6. With finger tips, seat the dust boot lip (1) into the boot groove in the caliper bore. Trace around the outside perimeter of the dust boot with a finger tip making sure the lip is properly seated in the groove and not much air is trapped behind the boot.
    Fig 5: Snap Ring Installation
    GC0083929Courtesy of CHRYSLER GROUP, LLC
  7. Position one end of the boot snap-ring (1) inside the boot outer lip (2), then making a circular motion, walk the snap-ring around the boot lip, completely installing and seating it.
  8. Inspect whether the two ends of the boot snap-ring are not overlapping one another. If they are, push the snap ring and dust boot further into groove removing any overlap of the snap-ring.
  9. Install the caliper on the vehicle and bleed the brakes as necessary. Refer to CALIPER, DISC BRAKE, REAR, INSTALLATION .
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