Caliper Removal and Installation

Removal

1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

Raise and support the vehicle.

2. Remove the wheel and tire assembly.





3. 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 and induce vomiting. Get medical attention immediately.

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

Disconnect the front brake hose.
1. Remove the front brake hose bolt.
2. Disconnect the front brake hose.
3. Remove and discard the copper washers. Plug the front brake hose.





4. Remove the disc brake caliper.
1. Remove the disc brake caliper bolts.
2. Lift the disc brake caliper off the front disc brake caliper anchor plate.





5. Inspect the disc brake caliper.
^ If leaks or damaged boots are found, disassembly is required.

Installation





1. CAUTION: Make sure guide pin boots are properly seated or damage to guide pins cam occur.

NOTE: Tighten the lower caliper bolt first.

Install the disc brake caliper.
1. Install the disc brake caliper.
2. Install the disc brake caliper bolts.





2. Install the front brake hose.
^ Use new copper washers; connect the front brake hose.
^ Install the front brake hose bolt.
3. Bleed the caliper.

4. NOTE: After the vehicle is on the ground, if equipped with air suspension, reactivate the system by turning on the air suspension switch.

Install the wheel and tire assembly.
5. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J1704-DOT 4. Install brake master cylinder filler cap.
6. Inspect the brake system operation.