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Assembly (Durango)

CAUTION: Dirt, oil, and solvents can damage caliper seals. Ensure assembly area is clean and dry.
  1. Lubricate caliper pistons, piston seals, and piston bores with clean, fresh brake fluid.
  2. Install new piston seals into caliper bores. See Fig 1.
    NOTE: Verify seal is fully seated and not twisted.
  3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at top of piston.
  4. Stretch boot rearward to straighten boot folds then move boot forward until folds snap into place.
  5. Install piston into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. See Fig 2.
  6. Seat piston dust boot using Handle (C-4171) and appropriate installer. See Fig 3.
    • HD 56-mm caliper - Installer (C-4340).
    • LD 54-mm caliper - Installer (C-3716-A).
  7. Install the second caliper piston and boot.
  8. Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar brake grease or Dow Corning® 807 grease only.
    CAUTION: Use of alternative grease may cause damage to the boots seals.
  9. Install the boot seals into the caliper seal bores and center the seals in the bores. See Figure.
  10. Install mounting bolt bushings into the boot seals and ensure seal lip is engaged into the bushing grooves at either end of the bushing.
  11. Install caliper bleed screw.
Fig 1: Installing Caliper Piston Seals
G00283100Courtesy of CHRYSLER CORP.
Fig 2: Installing Caliper Piston
G00283101Courtesy of CHRYSLER CORP.
Fig 3: Installing Caliper Piston Dust Boot
G00283102Courtesy of CHRYSLER CORP.
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