Caliper Removal and Installation, Rear

Brake Caliper

Material:

Disc Brake System - Exploded View, Rear:

Removal

WARNING: Use of any brake fluid other than the approved DOT 3 will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury.

CAUTION: Brake fluid is harmful to painted or plastic surfaces. Do not spill brake fluid onto painted or plastic surfaces. If spilled, wipe up immediately.

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 service switch. 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. Failure to follow these instructions may result in personal injury.

If equipped, turn the air suspension service switch to the OFF position.

2. WARNING: If equipped with fire suppression system, depower the system. For important safety warnings and procedures, refer to Fire Suppression System.

With the vehicle in NEUTRAL, position it on a hoist.
3. Remove the brake caliper flow bolt and disconnect the brake hose from the brake caliper.
^ Remove and discard the copper washers.
^ Plug the brake hose.

4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable.

Remove the 2 brake caliper bolts and the brake caliper.
5. Inspect the rear disc brake caliper for leaks and for binding slide pins.
^ If leaks or binding slide pins are found, install a new brake caliper.

Installation

1. NOTE: Make sure the anti-rattle clips are correctly positioned. Install new clips if worn or damaged.

Position the anti-rattle clip on the anchor plate rail.

2. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt.

NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper.

Position the brake caliper and install the 2 brake caliper bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
3. Position the brake hose and install the brake caliper flow bolt using 2 new copper washers.
^ Tighten to 50 Nm (37 ft. lbs.).
4. Bleed the brake system.

5. WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System.

If equipped with fire suppression system, repower the system.
6. If equipped, turn the air suspension service switch to the ON position.

7. NOTE: Apply the brakes several times before driving the vehicle.

Verify correct brake operation.