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Home >> Ford >> 1995 >> Windstar V6-232 3.8L >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Brake Caliper >> Service and Repair >> Rear
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Rear

DISASSEMBLY
1. Remove the rear disc brake caliper from the vehicle.
2. Remove the rear brake pad 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.
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 DOT 3 equivalent 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.
12. Lubricate the interior of the caliper bolt bushing boots and the exterior of the caliper bolt bushings with Silicone Lubricant C0AZ-19553-AA or equivalent meeting Ford specification ESR-M13P4-A.
13. Install the caliper bolt bushings into the caliper bolt bushing boots. Make sure the caliper bolt bushing boots are seated in the grooves in the caliper bolt bushings.
14. Install the inboard rear brake pad and lining. Make sure the spring clip is fully seated into the caliper piston.
15. Install the outboard brake pad 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.
16. Install the rear disc brake caliper on the vehicle.



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