Caliper Disassembly and Assembly
CaliperDisassembly
1. Remove the disc brake caliper.
2. Drain the remaining brake fluid from the disc brake caliper.
3. Apply low air pressure to the fluid port in the disc brake caliper.
1 Place a block of wood between the caliper bridge and the caliper pistons.
2 Apply low air pressure to the fluid port in the disc brake calipers and force out the caliper pistons to the block of wood.
3 Remove the block of wood and the caliper pistons.
4. Remove the piston seals and boots.
1 Remove the piston boot retainer.
2 Remove and discard the piston boots and seals.
5. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores.
If the caliper bores are excessively scored or corroded, replace the disc brake caliper.
Assembly
CAUTION: Never reuse piston seals and dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time.
1. Lubricate the piston boot, caliper piston, piston seal and caliper bores with clean High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
2. Install the caliper pistons.
1 Install the piston seal.
2 Install the piston boot on the piston.
3 CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
4 CAUTION: Be careful not to cock the caliper piston.
Position the boot in the bore, and press the caliper piston into the bore.
5 Install the piston boot retainer.
3. Install the disc brake caliper.