Caliper Disassembly and Assembly
DisassemblyWARNING: Use of any other than approved DOT 4 or DOT 3 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. Remove the caliper.
2. Drain the remaining brake fluid from caliper.
3. Apply low air pressure to the fluid port in the 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 caliper and force out the caliper pistons to the block of wood.
4. Remove the caliper pistons.
1 Remove the block of wood.
2 Remove the caliper pistons.
5. Remove and discard the piston seals and boots.
6. Remove and discard the bleed screw and cap.
Assembly
1 CAUTION: Do not hone the caliper bores. Caliper pistons are not available for honed caliper bores.
Clean and inspect the caliper pistons and the caliper.
- Remove dirt and debris.
- Examine the caliper pistons for surface irregularities, scoring or wear. Install new caliper pistons if necessary.
- Clean the caliper bores with Brake Parts Cleaner F6AZ-2C410-AB.
If the caliper bores are corroded or excessively scored, install a new caliper.
- Lubricate the caliper pistons and piston seals before assembly.
2. 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.
Lubricate the caliper piston, piston seal and caliper bores with clean High Performance DOT 4 Brake Fluid or equivalent DOT 4 fluid meeting Ford specification SAE-J1704-DOT 4. If DOT 4 is not available use DOT 3 Brake Fluid (United States only) C6AZ-19542-AB meeting Ford specification ESA-M6C25-A.
3. CAUTION: Pistons are not the same diameter.
Install the caliper piston.
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.
Press the caliper piston into the bore.
4. Install a new bleed screw and cap.
5. Install the caliper.