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Home >> Dodge and Ram >> 1999 >> Viper RT-10 V10-8.0L VIN E >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Brake Caliper >> Service and Repair >> Disassembly and Assembly >> Front >> Outboard Caliper Half

Outboard Caliper Half

Removing Piston From Caliper Bore:





1. Lay a shop towel over the outboard caliper half to protect the finish on the caliper. Place an appropriate size tool such as the seal installer or an equivalent, over the caliper piston and dust boot which had been reconditioned. Using a C-clamp, hold the seal installer or equivalent tool in place over the top of the caliper piston. Tighten the C-clamp just enough to hold the pieces in place, DO NOT USE EXCESSIVE FORCE this could damage the caliper or piston.
2. Place a shop towel in the center area of the caliper. This is to protect the piston and the caliper from damage, when the piston is removed from the bore of the caliper.

WARNING: WHEN REMOVING THE PISTON FROM THE BORE OF THE CALIPER DO NOT PLACE HANDS OR FINGERS INTO THE CENTER AREA OF THE CALIPER. HAND INJURY WILL OCCUR WHEN THE PISTON COMES OUT OF THE BORE OF THE CALIPER.

3. Using ONLY a rubber tipped air nozzle, insert the nozzle into the port for the interconnecting brake fluid line on the end of outboard half of the caliper. Slowly apply just enough air pressure to slowly push the unclamped piston out of the bore of the caliper.

Removing Dust Boot From Caliper:





4. When removing the piston from the bore of the caliper, the dust boot may remain in the caliper. If the dust boot does not come out with the piston, carefully pry the dust boot from the counterbore of the caliper using a small screw driver. The screwdriver is to be inserted between the outer edge of the dust boot and the counter bore of the caliper. Do not insert the screw driver into the piston bore of the caliper to remove the dust boot, piston bore scoring can occur.





5. Remove the dust boot from the piston. Then clean the piston using alcohol or other suitable solvent and wipe dry. Inspect all surfaces of the piston for any signs of corrosion or scoring. If the corrosion on the piston can not be removed using the solvent or the piston is scored the piston must be replaced. The piston can not be sanded to remove any of the corrosion or scoring.

Removing Piston Seal From Caliper Bore:





6. Remove the piston seal from the outboard caliper piston bore using a sharpened pencil, trim stick or other suitable tool. Do not use a screwdriver or any other metal tool for this operation, due to the possible scratching of the caliper bore or burring the edges of the seal groove.

CAUTION: The caliper used on the Viper does not have piston bores which can be honed. If a piston bore of the caliper cannot be cleaned using solvent, the caliper must be replaced.

7. Clean the bore of the caliper using alcohol or another suitable solvent saturated into a lint free towel. When thoroughly cleaned, wipe the bore of the caliper dry using a clean lint free towel. Inspect all surfaces of the caliper bore for any signs of corrosion or scoring. If the corrosion on the bore of caliper can not be removed using solvent or the bore is scored, the caliper assembly must be replaced. Do not attempt to hone the bore of the caliper to remove the corrosion or scoring.
8. Using compressed air, blow out the caliper piston bore to remove any particles that may be left from the cleaning procedure and to ensure caliper bore is dry.

Piston Seal Installed In Caliper:





9. Dip the new piston seal in fresh clean brake fluid. Position the seal into the seal groove in the piston bore of the caliper. Then using your fingers gently work piston seal into seal groove in caliper bore until the seal is properly seated.
10. Lightly coat the inside of the new dust boot with fresh clean brake fluid. Then install the new dust boot on the caliper piston. Be sure the dust boot is completely seated in the retaining groove of the piston.

CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper.

Piston Installed In Caliper Bore:





11. Squarely install the piston into the top portion of caliper bore. Then using your fingers evenly apply pressure to the piston, pressing it into the bore of the caliper until it is past the piston seal and bottomed in bore.





12. Position the dust boot in the counterbore of the caliper bore. Using your fingers install the dust boot into the counterbore until it is flush with the face of the caliper surface.
13. Move the C-clamp and seal installer to the caliper piston which has just been reconditioned. This will hold the piston in place while reconditioning the remaining inboard caliper piston.
14. Repeat steps Step 2 through Step 12 on the remaining piston in the inboard half of the caliper assembly. When these steps are completed the outboard half of the caliper assembly service is completed.
15. Install the front disc brake calipers on the front steering knuckles of the vehicle.
16. Bleed front brake calipers. See Brake Bleeding for the required bleeding procedures.
17. Install the wheel and tire assemblies.
18. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 122 Nm (90 ft. lbs.).
19. Lower the vehicle to the ground. Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle.
20. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. See Brake Burnishing in Service and Repair for the correct procedure if NEW brake shoe assemblies were installed.


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