Hi guys, I've been working on my rear calipers after dealing with issues of the e-brake seizing without returning. Turns out the inside of my calipers were all seized with dirt and crap making it incredibly difficult to move the lever (too much for the spring to overcome). After taking both off I decided my RH caliper was messed with by some idiot in the past who completely ruined them, and I determined is was going to be junk, so I ordered a replacement one. The LH one still has good internals, but I believe the main piston dust seal was allowing tons of dirt and brake dust in over the years. I cleaned the caliper up, painted it and ordered a replacement seal kit which arrived yesterday. I went and tried to size up the dust seal and it fits loosely in the groove. I've never heard of this because it seems every thread I looked at, the only problem people had with installing it was that they are a little too big and hard to press in. It sits on the actual piston fine, but I don't know why the outer diameter is so small and does not seat properly. Is it possible I need to use an adhesive or grease to hold it there? I ordered an ACDELCO hydraulic and dust seal kit for an 84 fiero from RockAuto.

Do Not use "Glue" or anything else to install any seal/boot on the brakes.
Only lube outer seal and plastic "shim" for park brake screw that lives between cal body and arm. That and the sliders needs Brake Grease.
See my Cave, Brake Service

Dust boots go on the piston before install in the caliper.
Then Outer side gets "pressed" into the cal body.

The Press uses a cup to press the boot w/o loading on the piston. Can make a "cup" out of standard plastic pipe parts then carefully press w/ standard bearing/seal drivers for front wheel bearings/seals.

Inner diam maybe a bit loose but if piston doesn't seal then will have crap water and more getting in and likely sooner then later.
Outer diam should only fit when pressed in the cal body.

First issue is RockAuto... Expect problems if you need to return parts.
Go to AZ, AdvanceAuto, etc. that often can return warranty and cores to local stores.

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Dr. Ian Malcolm: Yeah, but your scientists were so preoccupied with whether or not they could, they didn't stop to think if they should.
(Jurassic Park)

The Ogre's Fiero Cave

quote Originally posted by theogre: Inner diam maybe a bit loose but if piston doesn't seal then will have crap water and more getting in and likely sooner then later. Outer diam should only fit when pressed in the cal body. First issue is RockAuto... Expect problems if you need to return parts. Go to AZ, AdvanceAuto, etc. that often can return warranty and cores to local stores.

Hey Ogre, thanks for the help, I will tour your cave to get a better understanding

Outer diameter on the dust seal is definitely too small, I am able to place it in the caliper body with plenty of room to spare.. Damn RockAuto..

I was going to push in the piston using your pvc pipe/c-clamp method but I got stopped when I found out this seal didn't fit properly..