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Nate,
I vaguely remember having had same experience with the boot. Yes it can be tough. My memory is dimm, but here's what I recall.
I had removed the piston from the cylinder, did a nice job cleanning it and the cylinder housing with brake fluid. DID YOU DO THIS? I just mention this because you state that you used a "spray" to loosen things up. If that's WD40 or something like it, it won't agree very well with brake fluid. Clean everything with brake fluid before re-assembly.
Back to the boot. On my first attempt I pushed the pistion all the way in and tried to the fit the boot. The outer part that hooks to the pistion is real easy, the part that goes to the cylinder housing wouldn't go in. I next tried with the piston removed. I could easily seat the boot into the cylinder housing, but couldn't slip the pistion into the smaller outer diameter part of the boot. So I tried a compromise. With pistion out of the housing, I slipped the big end of the boot over the pistion. I then continued pulling (gently and slowly, but with determination!)and got the small end of the boot to slide onto the body of the piston. Yes it was tight, but it didn't rip or get permenantly streched. I continued sliding the boot down the piston until the big end of the boot was off the pistion by about 1/2". When I offered this to the housing, the lips of the boot's big end seated w/o too much trouble. I then carefully pushed the cylinder into the housing, and when it was in far enough, I slid the small end of the boot outward, to the front on the piston, where it immediately found its place and snapped right in.
Hopefully you are using a new boot, and a new seal for this? I don't know if an old boot and tolerate the abuse of installation, and I'd be concerned that the old seal will be reliable. On the other hand, the second time you do this will go easier since you'll have had practice!
remember, wash everything with brake fluid before installation.
good luck
Ed N
posted by 130.167.237...
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