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Home >> Ford >> 1995 >> Explorer 4WD V6-245 4.0L >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Brake Caliper >> Service and Repair >> Rear >> Rebuild

Rebuild










Item Part Number Description

1. 2001 Brake Shoe and Lining, Outboard
2. 2001 Brake Shoe and Lining, Inboard
3. -- Anti-Rattle Clip (Part of 2001)
4. 2552 Rear Disc Brake Caliper
5. -- Caliper Bolt Bushing Dust Boot (Part of 2552)
6. -- Caliper Bolt Bushing (Part of 2552)
7. -- Bleeder Screw Cap (Part of 2208)
8. 2208 Bleeder Screw
9. -- Anti-Rattle Clip (Part of 2001)







Item Part Number Description

1. -- Spring Clip (Part of 2001)
2. 2001 Brake Shoe and Lining, Inboard
3. 2001 Brake Shoe and Lining, Outboard
4. -- Spring Clip (Part of 2001)
5. 2207 Dust Boot
6. 2B115 Piston Seal
7. 2196 Caliper Piston
8. 2552 Rear Disc Brake Caliper

DISASSEMBLY
1. Remove the rear disc brake caliper (2552) from the vehicle. Refer to Removal and Installation, Caliper in this section.
2. Remove the rear brake shoe and lining from the rear disc brake caliper.
3. Remove the caliper bolt bushings and caliper bolt bushing dust boots from the rear disc brake caliper only if service is required.

CAUTION: Do not use petroleum or mineral based service greases (such as Ford Disc Brake Caliper Slide Grease D7AZ-19590-A or equivalent) for this application. Such greases will cause rapid deterioration of the slide pin boots. Service life of the disc brakes could be reduced as a result.

NOTE: Do not remove the guide pins or guide pin boots unless a problem is suspected.The caliper guide pins are covered by a flexible boot and are intended to be lubed for life. At time of publication, there was no approved material or procedure for re-lubing the caliper slide pins. For routine service such as brake pad replacement, the slide pins, grease and boots should be reused as are, if not damaged. If damaged, new pins (with new boots and grease included) must be installed.

4. Pad the rear disc brake caliper jaws with shop towels or equivalent to avoid damage to the disc brake caliper piston when it is forced out of the rear disc brake caliper bore.

5. Using a rubber-nosed air nozzle at the brake fluid inlet port, apply low pressure air to force the disc brake caliper piston out of the caliper bore.

WARNING: To Avoid Damage Or Injury, Use Only Enough Air Pressure To Expel The Piston. Do Not Attempt To Catch The Piston As It Is Forced Out Of The Rear Disc Brake Caliper.

6. Using a suitable tool, pry the caliper piston dust boot out of the rear disc brake caliper bore.
7. Remove and discard the rear disc brake caliper piston seal from the caliper bore.

CAUTION: To avoid damage to the bore or seal seat, use only a non-metallic tool to remove the piston seal.

ASSEMBLY
1. Clean and inspect the rear disc brake caliper bore for scoring, rust, pitting or other damage. Do not hone a worn or damaged caliper bore. A new rear disc brake caliper must be used.
2. Clean and inspect the caliper piston for cracks or other damage. Do not attempt to repair a worn or damaged caliper piston. A new one must be installed.
3. Clean and inspect the caliper dust boot, caliper bolt bushings and caliper bolt bushing boots. Replace if worn or damaged.
4. Lubricate the caliper bore, new piston seal and the caliper piston with clean Ford High-Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 meeting Ford specification ESA-M6C25-A.
5. Install the new piston seal into the caliper bore seal groove. Make sure the seal is not twisted and is fully seated.
6. Install the caliper piston into the caliper bore past the piston seal. Use a rocking, twisting motion and use care not to distort the piston seal.
7. After the caliper piston is past the piston seal, press the caliper piston about 2/3 into the caliper bore.
8. Install the dust boot on the caliper piston.
9. Using Piston Dust Seal Replacer T92P-2588-AH and Driver Handle T80T-4000-W seat the dust boot into the caliper bore. Make sure the dust boot is fully seated into the caliper piston groove and caliper bore groove.
10. After installing the dust boot, press the caliper piston to the bottom of the caliper bore.
11. Install the caliper bolt bushing boots into the rear disc brake caliper only if required.

NOTE: Do not remove the guide pins or guide pin boots unless a problem is suspected. The caliper guide pins are covered by a flexible boot and are intended to be lubed for life. At time of publication, there was no approved material or procedure for re-lubing the caliper slide pins. For routine service such as brake pad replacement, the slide pins, grease and boots should be reused as are, if not damaged. If damaged, new pins (with new boots and grease included) must be installed.

CAUTION: Do not use petroleum or mineral based service greases (such as Ford Disc Brake Caliper Slide Grease D7AZ-19590-A or equivalent) for this application. Such greases will cause rapid deterioration of the slide pin boots. Service life of the disc brakes could be reduced as a result.

12. Make sure the caliper bolt bushing boots are seated in the grooves in the caliper bolt bushings.
13. Install the inboard brake shoe and lining. Make sure the spring clip is fully seated into the caliper piston.
14. Install the outboard brake shoe and lining into the rear disc brake caliper. Make sure the locating lugs are positioned in the mating holes in the rear disc brake caliper.
15. Install the rear disc brake caliper on the vehicle.
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