Caliper Removal and Installation, Front

Brake Caliper

Material:

Front Brake Components - E-150:

Front Brake Components - E250, E-350, Single Rear Wheel:

Front Brake Components - E-350, E-450 and Dual Rear Wheel:

Removal

WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

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. Failure to follow these instructions may result in personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.





2. Release the speed sensor wiring from the front brake hose.
3. Remove the brake caliper flow bolt and position the brake flexible hose aside.
^ Discard the 2 copper washers.

4. CAUTION: Do not pry in the caliper sight hole to retract the pistons as this can damage the pistons and boots.

Remove the 2 brake caliper bolts and the brake caliper.
^ If leaks or damaged boots are found, install a new disc brake caliper.

Installation

1. CAUTION: Tighten the bottom caliper bolt before tightening the top caliper bolt.

CAUTION: Make sure the caliper pin boots are correctly seated to prevent damage to the guide pins.

Position the brake caliper and install the 2 brake caliper bolts.
^ On E-150, tighten to 32 Nm (24 ft. lbs.).
^ On E-250, E-350, E-450, tighten to 31 Nm (23 ft. lbs.).

2. Using 2 new copper washers, position the brake flexible hose and install the brake caliper flow bolt.
^ Tighten to 35 Nm (26 ft. lbs.).





3. Attach the speed sensor wiring to the front brake hose.
4. Bleed the brake caliper.
5. Test the brake system for normal operation.