Caliper Disassembly and Assembly

Special Tools:

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





4. Remove the caliper piston.
1. Place a block of wood between the caliper bridge and the caliper piston.
2. Apply low air pressure to the fluid port in the rear disc brake caliper.
3. Force out the caliper piston to the block of wood.
4. Remove the block of wood and the caliper piston.





5. Note: Do not hone the cylinder bore. Caliper pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore is excessively scored or corroded, replace the rear disc brake caliper.

Remove and discard the piston seal and dust boot.

Assembly

CAUTION: Never reuse the piston seal or dust boot.

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 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A.
^ Cylinder bore.
^ Piston seal.
^ Caliper piston.
^ Dust boot.





2. Install the piston seal.





3. Install the dust boot.





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

Install the caliper piston.
5. Install the rear disc brake caliper.