> I am trying to fit new pistons into new seals.
>
> The manual says to:
> - fit the seal into the bore - done.
> - fit the dust cover lower edge into the caliper groove - aargh (not done).
This step is critical ... if the dust cover doesn't seat into the groove, then
you can't push the piston past it.
> - slide the piston through the dust cover and past the bore seal into
> the caliper - tried this first and it won't get past the seal even
> with liberal amounts of new fluid.
>
> What is the trick in getting the dust cover in place and then
> managing to keep it there while I try and fight the piston past the
> seal without damaging it?
I use a small, blunted screwdriver to lift the dust cover around the piston. It
takes some skill to push the piston into the bore, it must be exactly aligned or
it will bind. Usually, taking a short break to inspect will allow you to see
how it is cocked, so apply pressure only on the high side until it cocks the
other way. As I recall (it's been a long time, I love DOT 5 !) I used a
combination of pry bars, big C-clamps and swear words to coax it in.
Randall
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