Chrysler 1997 Stratus Convertible RHD Service Manual page 160

CALIPER
5 - 58 BRAKES
DISASSEMBLY AND ASSEMBLY (Continued)
the bore is not increased more than 0.0254 mm
(0.001 inch) (Fig. 162).
Fig. 162 Honing Brake Caliper Piston Bore
(11) If the bore does not clean up within this spec-
ification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or scored.
NOTE: When using Caliper Honing Tool, Special
Tool C-4095, coat the stones and bore with brake
fluid. After honing the bore, carefully clean the seal
and boot grooves with a stiff non-metallic rotary
brush.
NOTE: Use extreme care in cleaning the caliper
after honing. Remove all dirt and grit by flushing
the caliper with brake fluid; wipe dry with a clean,
lint free cloth and then clean a second time.
CAUTION: When inspecting caliper piston, do not
use anything but solvents to clean piston surface. If
surface of piston cannot be cleaned using only sol-
vents, piston must be replaced.
(12) Inspect caliper piston for pitting, scratches, or
any physical damage. Replace piston if there is evi-
dence of scratches, pitting or physical damage.
CALIPER ASSEMBLY
CAUTION: Excessive vise pressure will cause bore
distortion and binding of piston.
(1) Clamp caliper in a vise (with protective caps
installed on jaws of vise).
CALIPERBORE SPECIAL TOOL C-4095 CALIPER
(2) Dip new piston seal in clean brake fluid and
install in the groove of the caliper bore. Seal should
be positioned at one area in groove and gently
worked around the groove (Fig. 163), using only your
fingers until properly seated. NEVER USE AN OLD
PISTON SEAL. Be sure that fingers are clean and
seal is not twisted or rolled (Fig. 163).
Fig. 163 Installing New Piston Seal In Caliper
(3) Coat new piston boot with clean brake fluid
leaving a generous amount inside boot.
(4) Position dust boot over piston after coating
with brake fluid.
CAUTION: Force must be applied to the piston uni-
formly to avoid cocking and binding of the piston in
the bore of the caliper.
(5) Install piston into caliper bore pushing it past
the piston seal until it bottoms in the caliper bore
(Fig. 164).
CALIPER
Fig. 164 Installing Piston Into Caliper Bore
SEAL GROOVE PISTON SEAL
JX
PISTON BOOT