Disc Brake Calipers: Assembly

WARNING: This page is about a different car, the 2006 Jeep Grand Cherokee. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Installing New Piston Seals Into Caliper Bores - Except SRT-10

Courtesy of DAIMLERCHRYSLER CORP.

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

Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid.
NOTE: Verify seal is fully seated and not twisted.
Install new piston seals (3) into caliper bores (2).

Fig 2: Installing Piston Into Caliper Bore - Except SRT-10
Courtesy of DAIMLERCHRYSLER CORP.
Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3).
Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place.
Install piston (3) into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle.

Fig 3: Seating Dust Boot In Caliper - Except SRT-10
Courtesy of DAIMLERCHRYSLER CORP.
Seat dust boot in caliper (2) with Handle C-4171 (1) and Installer (3).
Install the second piston and dust boot.
Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar brake grease or Dow Corning® G407 grease only.
CAUTION: Use of alternative grease may cause damage to the boots seals.
Install the boot seals into the caliper seal bores and center the seals in the bores.
Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing.
Install caliper bleed screw.