Caliper Disassembly and Assembly

Disassembly
1. Remove the rear disc brake caliper.
2. Drain remaining brake fluid from the rear disc brake caliper.
3. Secure the rear disc brake caliper.





4. Remove the caliper pistons.
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 rear disc brake caliper.
3 Force out the caliper pistons to the block of wood.
4 Remove the block of wood and the caliper pistons.

Part 2 Of 4:

Part 3 Of 4:

Part 4 Of 4:

5. Remove and discard the piston seals and boots.

6. NOTE: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores.

If the rear disc brake caliper is leaking, replace the piston seals. If the cylinder bores are excessively scored or corroded, replace the rear 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 following with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A:
- Dust boots.
- Caliper pistons.
- Piston seals.
- Cylinder bores.





2. Install the caliper pistons.
1 Install the piston seals.
2 Install the dust boots.

3 CAUTION: Be careful not to damage or dislodge the piston seal.

Insert the caliper pistons.
4 Press the caliper pistons into the cylinder bore being careful not to cock the caliper pistons.

3. Install the rear disc brake caliper.