Caliper Disassembly and Assembly

Caliper





Special Tool(s)

Disassembly

WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative.

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water to induce vomiting. Get medical attention immediately.

CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

1. Remove the rear disc brake caliper.
2. Drain the remaining brake fluid from the rear disc brake caliper.
3. Secure the rear disc brake caliper in a vise.





4. Remove the rear disc brake piston.
^ Place a block of wood between the caliper bridge and the rear disc brake piston.
^ Apply low air pressure to the fluid port in the rear disc brake caliper.
^ Force the rear disc brake piston out to the block of wood.
^ Remove the block of wood and the rear disc brake piston.





5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore/piston is excessively scored or corroded, install a new rear disc brake caliper.

Remove and discard the piston seal and dust boot.

Assembly

CAUTION: Never reuse the piston seal or dust boot.

NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time.





1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
^ cylinder bore
^ piston seal
^ rear disc brake piston
^ dust boot





2. Install the piston seal.





3. Install the dust boot.





4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear disc brake piston.

5. Install the rear disc brake caliper.