I have an 85 300TD and it needed a good seal & pad replacement and cleanup. I managed to get out the pistons and clean everything all up and get the new seals in and seat the pistons back in. But now I cant get the new dust covers back on.

I bought FTE Caliper repair kits for ATE rear calipers from Bimmerspecialist online. The seals went in fine but the dust covers have a problem getting fully seated on all the way around the outer groove of the piston housing.

Its as if its almost on but as you work your fingers around to the other side where its sticking out a bit, and push down, the other side pops up again. Its as if the metal ring inside the rubber is a touch too small.

Is there something that should be done to prep it? I already made some holes trying to press down on the rubber ring having the metal cookie-cut the rubber from underneath with the pressure of a metal screwdriver...(bad Idea) What a drag. For a couple pieces of rubber it cost me $20, per side.
Any Ideas of what the problem may be?
Thanks!
michael

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