Caliper Assembly

1. Clamp caliper in a vise (with protective caps installed on jaws of vise). Dip new piston seal in clean brake fluid and install in groove of caliper bore. Seal should be positioned at one area in groove and gently worked around groove using only your fingers until properly seated never use a used piston seal. See Fig 11 . Be sure that fingers are clean and seal is not twisted or rolled.
2. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. Position dust boot over piston after coating with brake fluid. Install piston into caliper bore pushing it past piston seal until it bottoms in caliper bore. See Fig 12 .
   CAUTION: Force must be applied to piston uniformly to avoid cocking and binding of piston in bore of caliper.
3. Position dust boot into counterbore of caliper assembly piston bore. Using a hammer and Installer Piston Caliper Boot (Special Tool C-4689) and Handle (Special Tool C-4171), drive boot into counterbore of caliper. See Fig 13 . Install guide pin sleeves and bushings. See Install Guide Pin Bushings section in caliper disassembly section of this manual. Install brake pads. Before installing caliper assembly on vehicle, inspect brake rotor. If any conditions as described in Checking Brake Rotor for Runout and Thickness are present rotor, must be replaced or refaced. If rotor does not require any servicing, install caliper assembly.
4. Install brake hose onto caliper using banjo bolt. Torque brake hose to caliper assembly banjo bolt to 33 N.m (24 ft. lbs.). New seal washers MUST always be used when installing brake hose to caliper. Bleed brake system.