Brake piston dust shield install problem
 

I'm rebuilding the rear calipers on my Carrera... ran into a snag.

I'm having difficulty getting the dust covers to stay seated to the caliper. I can't seem to apply enough pressure all the way around them to get them to seat themselves. When I push down hard on one side, the opposite side pops out. Is there a trick to this? Or a special tool I need?

BTW, I've never had a caliper apart before this project. I always figured they were a lot more complex than they are!!! Drop dead simple, but effective, technology -- the best kind!

John,

I had that same problem. Get a penny and a small wood rod or pencil that is about as long as the distance between the two brake pistons. The penny is only needed to protect the dust boot.

Start seating the dust cover and on one end place the penny on the seal and then hold it in place by wedging the rod against the other side of the caliper. With the cover held in place on one end, you should be able to seat the whole thing with out it popping out.

My instructions aren't that clear, but once you get the rod and penny together, it should become evident.

Check out the search funtion. You can make it real easy if you go buy a jar of gerbers baby food and use the lid to push on the dust cover. I am passing on something that I used and got the info here. Works real slick

Had the same problem. Make sure there is no lubricant\fluid on the rubber or lip of the caliper and it will stay in place much better and won't slide off.,

Also, make sure the notches in the piston are aiming in the correct orientation when you put it together

I read in Wayne's book that it helps to have the rear pistons out a little bit. I don't if this is applicable to a Carrera, but I thought I'd mention it.

I use a steel ring the same diameter as the seal ring and a vise.

Pop! goes the weasel.

Thanks, all, for the great suggestions!!

The NoVA Porsche Board came up with one I'm gonna try (when I get the time). It turns out a Gerber baby food jar lid is the same size as the rear caliper dust seals and it has a nice smooth rolled over edge that shouldn't tear the rubber. Hope it works!