Caliper Disassembly and Assembly, Front

Front Brake Caliper

Disassembly

1. WARNING: Use of any other than approved DOT 3 or DOT 4 brake fluid will cause permanent damage to brake components and will render 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 medial 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 with water.

Drain brake fluid from the disc brake caliper.
2. Secure the disc brake caliper in a vise.
3. Remove the caliper piston.
1 Place a wood block between the caliper bridge and the caliper piston.
2 Apply low air pressure to the fluid port of the disc brake caliper.





3 Force the caliper piston out to the wood block. Remove the wood block and the caliper piston.
4. Remove and discard the caliper piston seals and dust boots.

5. NOTE: Do not hone the caliper bores. Caliper pistons are not available for honed calipers.

If the front disc brake calipers are leaking, install new caliper seal kits. If the caliper bores are damaged, install a new front disc brake caliper.

Assembly

1. CAUTION: Do not reuse piston seals or dust boots. Damage to the vehicle can occur.

NOTE: Use new brake fluid for assembly and bleeding of the brake system.

If DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE J1704.
Lubricate these brake system components with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A, DOT 3:
1 Piston dust boot.
2 Piston seal.
3 Caliper piston.
4 Caliper bore.





2. Install the caliper piston.
1 Install the caliper piston seal.
2 Install the caliper piston dust boot.

3 CAUTION: Use care when installing the caliper piston, or damage to the caliper piston seal or dust boot may occur.

Install the caliper piston into the caliper bore.





4 Press the caliper piston into the caliper bore. Use even pressure while making sure the piston does not cock.