Disc Brake Calipers: Assembly

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry.

Lubricate caliper piston bore, new piston seal and piston with clean brake fluid.
Lubricate caliper bushings and interior of bushing boots with silicone grease.
Install bushing boots in caliper, then insert bushing into boot and push bushing into place. See Fig 1.

Fig 1: Bushings And Boots Installation - Typical
Courtesy of DAIMLERCHRYSLER CORP.

1 - BUSHING

2 - BOOT
Install new piston seal into seal groove with finger. See Fig 2.

Fig 2: Piston Seal Installation - Typical
Courtesy of DAIMLERCHRYSLER CORP.

1 - SEAL GROOVE

2 - PISTON SEAL
Install new dust boot on caliper piston and seat boot in piston groove. See Fig 3.

Fig 3: Dust Boot On Piston - Typical
Courtesy of DAIMLERCHRYSLER CORP.

1 - PISTON

2 - DUST BOOT
Press piston into caliper bore by hand, use a turn and push motion to work piston into seal. See Fig 4.

Fig 4: Caliper Piston Installation - Typical
Courtesy of DAIMLERCHRYSLER CORP.

1 - PISTON

2 - BOOT
Press caliper piston to bottom of bore.

Seat dust boot in caliper with Installer Tool C-4842 and Tool Handle C-4171. See Fig 5.

Fig 5: Piston Dust Boot Installation - Typical

Courtesy of DAIMLERCHRYSLER CORP.

1 - HANDLE C-4171

2 - INSTALLER C-4842

3 - DUST BOOT

Replace caliper bleed screw if removed.