Caliper Disassembly and Assembly

Special Tool(s)

Disassembly and Assembly

WARNING: Use of any other than approved DOT 3 or DOT 4 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 and 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. Drain the brake fluid from the rear disc brake caliper.
2. Secure the rear disc brake caliper in a vise.





3. Using the special tool, turn the rear disc brake piston and adjuster counterclockwise.





4. Remove the rear disc brake piston and adjuster from the caliper bore.
5. Remove and discard the piston dust boot seal and piston seal from the caliper bore.





6. CAUTION: The parking brake lever pin retainer clip and spring cover are spring-loaded. Use care when removing the parking brake lever pin retainer clip.

Remove the parking brake lever pin retainer clip.
^ Unload the spring tension from the parking brake lever pin retainer clip and spring cover using the special tool, a 6-mm washer head nut and a 1/2-inch drive 14-mm socket.
^ Remove the parking brake lever pin retainer clip with suitable snap-ring pliers.
^ Remove the special tool, nut and socket.





7. Remove the following components:
1 Spring cover
2 Spring
3 Washer
4 Key plate
5 Push rod
6 Strut pin
7 Push rod O-ring
8. Remove and discard the O-ring seal from the push rod.





9. Remove the parking brake lever.
1 Remove the parking brake return spring.
2 Remove the limiting bolt.
3 Remove the parking brake lever.
4 Remove the parking brake lever shaft seal from the caliper bore.

10. CAUTION: Do not reuse piston seals or dust boots. Install new seals or dust boots or damage to the vehicle can occur.

NOTE: Use new brake fluid when assembling the disc brake caliper.

NOTE: Lightly lubricate the parking brake lever bore, limiting bolt, parking brake lever shaft and parking brake shaft recess with Silicone Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A.

To assemble, reverse the disassembly procedure.