FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Mercury >> 1997 >> Mystique L4-122 2.0L DOHC VIN 3 SFI >> Repair and Diagnosis >> Brakes and Traction Control >> Hydraulic System >> Brake Caliper >> Service and Repair >> Rear

Rear

CAUTION:
^ Do not allow the brake master cylinder reservoir to run dry during service operations. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse brake fluid that has been drained from the hydraulic system.

WARNING: BRAKE FLUID HAZARDS
^ 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 AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY.
^ USE ONLY AS MUCH COMPRESSED AIR AS NECESSARY TO REMOVE THE PISTON. EXCESSIVE PRESSURE CAN FORCE THE PISTON OUT OF THE BORE WITH ENOUGH FORCE TO CAUSE PERSONAL INJURY. NEVER ATTEMPT TO CATCH THE PISTON BY HAND AS IT COMES OUT OF THE BORE.

DISASSEMBLY

Rear Disc Brake Caliper:





1. Remove rear disc brake caliper. [1][2]Front
2. Using rear caliper piston adjuster, turn rear disc brake piston and adjuster counterclockwise to remove rear disc brake piston and adjuster from the rear disc brake adjuster spindle. Remove rear disc brake piston and adjuster from rear disc brake caliper housing.





3. Remove dust cover.

CAUTION: Use a plastic or wooden pick to remove the piston seal. A metal tool can scratch or nick the piston seal groove and possibly cause a leak.

4. Remove and discard caliper piston seal.
5. Remove disc brake caliper locating pin and disc brake caliper locating pin seals from caliper housing.
6. Remove brake bleeder screw dust cap and brake bleeder screw.
7. Inspect disc brake caliper locating pin bushings in caliper housing. If damaged or worn remove with a drift punch.





8. Remove plastic cover, tie strap and dust boot from parking brake actuator lever and caliper housing.
9. With caliper mounted in soft jaw vise, push on cupped washer to compress adjuster springs and remove parking actuator lever and cam.
10. Remove cup washer and brake adjuster springs from brake adjuster spindle. Note the stacking sequence of adjuster springs for reassembly.
11. Remove brake adjuster spindle and seal from caliper housing. Remove seal from brake adjuster spindle.

INSPECTION
CAUTION: Do not use denatured alcohol for flushing the system or cleaning assemblies where alcohol could be trapped and cause eventual failure of rubber components in the system. Denatured alcohol is acceptable for cleaning parts, provided the parts are completely air-dried and coated with brake fluid before installation.

^ Clean all metal parts with isopropyl alcohol. Use clean, dry compressed air to clean out and dry grooves and passages. Make sure caliper bore and component parts are completely free of any foreign material.
^ Inspect caliper bore for damage or excessive wear. If damaged, replace caliper assembly. If piston is pitted, scored or plating is worn off, replace rear disc brake piston and adjuster.
^ Inspect caliper locating pin bushings from damage or wear. Replace bushings if required.
^ Do not submerge caliper in cleaning solvent unless completely disassembled. The piston bore and outside of housing may be cleaned of contamination if required.

ASSEMBLY
1. Clean foreign material from rear disc brake piston and adjuster, brake adjuster spindle and caliper housing. Lubricate all internal surfaces with brake fluid before assembly.
2. Install new seal on brake adjuster spindle. With caliper housing mounted in soft jaw vise install brake adjuster into caliper housing.
3. Install brake adjuster springs and cup washer on brake adjuster spindle.
4. Apply pressure to cupped washer to compress adjuster springs and install parking brake actuator lever and cam.
5. Lubricate parking brake actuator lever and cam heavily with silicone dielectric compound.
6. Install dust boot over parking brake actuator lever and secure with a tie strap. Install plastic cover over dust boot.
7. If removed, install disc brake caliper locating pin bushings into caliper housing. Compress bushings and tap them in with a suitable diameter bushing driver or socket.
8. Lubricate disc brake caliper locating pin seals locator pin bushings and locating pin with silicone dielectric compound . Install disc brake caliper locating pin seals and locating pin into caliper housing.
9. Loosely install brake bleeder screw into caliper housing.
10. Install brake caliper piston and adjuster seal into groove in rear disc brake caliper housing.
11. Install dust cover onto rear disc brake piston and adjuster.
12. Lubricate inside of dust cover with silicone dielectric compound.
13. Using caliper piston adjuster, turn rear disc brake piston and adjuster clockwise to install into rear disc brake caliper housing.
14. Seat dust cover into rear disc brake caliper housing.
15. Install and bleed disc brake caliper.

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