FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Mercury >> 1999 >> Sable V6-3.0L DOHC VIN S >> Repair and Diagnosis >> Brakes and Traction Control >> Hydraulic System >> Brake Caliper >> Service and Repair >> Rear >> Disassembly and Assembly

Disassembly and Assembly

Special Tools:










Disassembly
1. Remove rear disc brake caliper assembly.
2. Mount rear disc brake caliper in a vise. Use vise-jaw protectors.





3. Using Rear Caliper Piston Adjuster 206-026 (T87P-2588-A), turn rear disc brake piston and adjuster counterclockwise and remove rear disc brake piston and adjuster from caliper piston bore.
4. Remove and discard piston dust boot seal and piston seal from caliper bore.





5. CAUTION: The parking brake lever pin retainer clip (circlip) and spring cover are under spring load. Care should be taken when removing the parking brake lever pin retainer clip (circlip) to prevent injury.

Release tension from parking brake lever pin retainer clip and spring cover using screw and crossblock (part of 206-SO27 (T87P-2588-B)), a 6 mm washer head nut and a 14 mm standard (1/2 inch) drive socket.
6. With suitable snap-ring pliers, remove parking brake lever pin retainer clip (circlip) retaining push rod assembly from rear disc brake caliper.
7. Remove spring cover, RH anti-rattle spring cover, washer, key plate and pull out push rod and strut pin from caliper bore.
8. Remove and discard rear brake caliper piston seal from push rod.
9. Remove parking brake return spring. Unscrew limiting bolt and pull parking brake lever out of caliper housing.


Assembly
1. Lightly grease parking brake lever bore and lever shaft seal with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A. Press parking brake lever shaft seal into caliper bore.





2. Grease parking brake shaft recess and slightly grease parking brake lever shaft. Insert shaft into bore in caliper housing.
3. Screw limiting bolt into caliper housing. Tighten to 6 - 9 Nm (54 - 79 inch lbs.). Attach parking brake return spring to limiting bolt and insert free end into parking brake lever slot.
4. Install a new rear brake caliper piston seal in groove of push rod. Grease recess at push rod end with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-MIC171-A.





5. Position pin into caliper housing and in recess of parking brake lever shaft. Install seal on push rod. Insert push rod into push rod bore of caliper housing. Make sure pin is positioned correctly in shaft recess and recess at end of push rod. Place locating washer over push rod so locating nib fits into drilled locating hole in caliper housing. Install flat washer, right hand anti-rattle spring and spring retainer in sequence.

Inner Spacer:





6. NOTE: Tools used in Steps 6 through 8 are part of Rear Caliper Spring Compressor Set 206-SO27 (T87P-2588-B).

Insert inner spacer into piston bore.





7. Place parking brake lever pin retainer clip inside of inner spacer.





8. CAUTION: Parking brake lever pin retainer clip should click into place. To prevent damage, do not overcompress. right hand anti-rattle spring.

Position spring compressor and screw and crossblock on push rod, and lightly screw tool clockwise to compress right hand anti-rattle spring. Install parking brake lever pin retainer clip (circlip).
9. Install new piston seal in groove in caliper housing after lubricating seal with High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT-3 equivalent meeting Ford specification ESA-MBC25-A. If DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4.

10. NOTE: Make sure one slot in rear disc brake piston and adjuster face is, positioned so it will engage with nib on brake shoe.

Coat rear disc brake piston and adjuster and piston dust boot with High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT-3 equivalent meeting Ford specification ESA-M6C25-A. If DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4. Install dust boot into piston bore of rear disc brake caliper. Spread dust boot over rear disc brake piston and adjuster and seat dust boot in piston groove. Rotate rear disc brake piston and adjuster clockwise using Rear Caliper Piston Adjuster 206-026 (T87P-2588-A) until piston is fully seated.
11. Install rear disc brake caliper assembly.


pro multis Credits:Operation CHARM About Operation CHARM