Caliper Disassembly and Assembly

Brake Caliper

Disassembly

WARNING: Use of any brake fluid other than approved DOT 3 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.

NOTE: Use clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent meeting Ford specification ESA-M6C25A.
^ Do not reuse brake fluid drained or bled from the system.
^ Do not use brake fluid that has been stored in an open container.
^ Do not use contaminated brake fluid.

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





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





5. Remove and discard the piston seals and boots.

6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores.

If the caliper bores are excessively scored or corroded, install a new disc brake caliper.

Assembly





1. CAUTION: Never reuse piston seals or dust boots.

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.

Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A.





2. Install the caliper pistons.
1. Install the piston seal.
2. Install the piston boot onto the piston.

3. CAUTION: Be careful not to damage or dislodge the piston seal.

Insert the caliper piston.
4. Press the caliper piston into the caliper bore, being careful not to cock the caliper piston and press the piston boot into the housing counter bore.
3. Install the disc brake caliper.