Caliper Removal and Installation

Caliper

Removal

WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled.

WARNING: Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents.

WARNING: If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators.

WARNING: Occupational health and safety act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area.

1. Raise and support the vehicle.
2. Remove the wheel and tire assembly.





3. 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 and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash it with water immediately.

Disconnect the brake hose.
1. Remove the brake hose bolt.
2. Disconnect the brake hose.
3. Remove and discard the copper washers. Plug the brake hose.





4. Remove the disc brake caliper.
1. Remove the disc brake caliper pin bolts.
2. Lift the disc brake caliper from the disc brake caliper anchor plate.





5. Inspect the disc brake caliper for leaks.
- If leaks are found, disassembly is required.

Installation




1. Install the disc brake caliper.
1. Install the disc brake caliper.
2. Install the disc brake caliper pin bolts.





2. Install the brake hose.
- Use new copper washers. Connect the brake hose.
- Install the brake hose bolt.
3. Bleed the brake system.
4. Install the wheel and tire assembly.
5. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Install the brake master cylinder filler cap.
6. Inspect the brake system operation.