Chrysler RAM TRUCK 2500 1994 Service Manual page 211

J9405-37
Fig. 24 Caliper Compc
CAUTION: Never hone the caliper piston bore, or
use any kind of abrasive material on the piston sur­
face. Honing will result in an oversize bore and
abrasives will damage the piston coating. Either of
these practices will result in piston bind and even­
tual seizure.
. Inspect condition of the threads i n the inlet and
bleed screw ports. Replace the caliper i f thread dam­
age is evident. Do not attempt to salvage the threads.
Check the bushings i n the caliper mounting bolt
bores. Replace the bushings i f worn, cut, or torn.
Bushing condition is important as they keep road
dirt and water from the mounting bolts.
DISC BRAKE CALIPER OVERHAUL AND
REASSEMBLY
(1) Be sure caliper assembly area of workbench is
clean and dry. This is important as dust, dirt, foreign
material, oil, or solvents can damage seals, harm pis­
ton surfaces and contaminate fluid.
(2) Lubricate caliper piston, piston seal and piston
bore with liberal quantity of clean, fresh brake fluid.
(3) Install new dust boot on piston as follows:
(a) Lightly lubricate lip of new boot with Dow or
GE silicone grease. Then work boot lip into boot
groove at top of piston (Fig. 25).
(b) Stretch boot rearward as shown to straighten
boot folds. Then move boot forward until folds snap
into place (Fig. 25).
(4) Install new seal on piston. Slide seal onto pis­
ton and seat in groove. Be sure square cut seal is
fully seated and is not twisted.
(80/86mm Caliper)
Fig. 25 Installing Dust Boot On Caliper Piston
(5) Install caliper piston. Apply more brake fluid to
piston, seal and bore. Then work caliper piston into