Caliper piston insertion force?
 

Full rebuild on all four calipers for my 964. I installed 7 pistons by hand with relative ease and then had several balk on me. Rather than tear something up, I thought I'd stop by and see how much force others have had to use to get these bits together.

I'm using factory rebuild kits, ATE Plastilube, and verify that the pistons fit into the bore before putting in the seals and attempting final install.

Do I just need more juice? (My manly forearms will be so chagrined...)

TIA!

When I do this I generally make sure the seal and cylinder wall is welll lubed with the ATE grease and use a clamp to gently bring her in. I'm not sure why some seem more stubborn than others. Even with the clamp I have to pay attention that the piston is being being drawn in evenly. If it doesn't go in easily with the clamp, it's not entering properly. Cheers

Thanks for that, Drisump. I went ahead and used a c-clamp as suggested. Seemed to go ok; the proof will be in the pudding I guess...

You should be good to go. One thing though, in my 3.2 you need to properly orient the relief on the surface of the piston that makes contact with the breke pad. Is it the same for the 964? I cut a wooden jig to ensure the proper alignment. Cheers

20 degree offset of centerline of piston...Jig can be cut from light cardboard. Cardboard backing from pad of paper.

All the pistons are flat-faced (well... ring-faced) with no differentiating features at all other than the diameter.