Voyager L4-2.4L VIN B (2001)
Installing Piston Into Caliper Bore
4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore.
5. Position the dust boot into the counterbore of the caliper assembly piston bore.
6. Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into
the counterbore of the caliper as necessary.
7. Reinstall the caliper on the vehicle and bleed the brakes as necessary.
Rear Disc Brake Caliper
DISASSEMBLY - CALIPER PISTON AND SEAL
WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER
BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE.
NOTE: Before disassembling the brake caliper, clean and inspect it.Refer to CLEANING or INSPECTION. The safest way to remove the piston
from the caliper bore is to use the hydraulic pressure of the vehicle's brake system.
1. Following the removal procedure in DISC BRAKE SHOES found in this section, remove the caliper from the brake rotor and hang the assembly
on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small
piece of wood between the piston and caliper fingers.
2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any
position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from
completely draining out.
3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle.
CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion.
4. Mount the caliper in a vise equipped with protective jaws.
5. Remove the piston dust boot from the caliper and discard.
NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove
edges.
