Caliper Disassembly and Assembly

Disassembly

WARNING: Use of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative.

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 to induce vomiting. Get medical attention immediately.

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

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





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





5. Remove and discard the piston seals and boots.

6. Note: Do not hone the caliper bores. Pistons are not available for honed caliper bores.

If the caliper bores are excessively scored or corroded, install a new disc brake caliper.

Assembly





1. CAUTION: Never reuse piston seals or 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.

Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A.





2. Install the caliper pistons.
1. Install the piston seal.
2. Install the piston boot.

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

Insert the caliper piston.
4. Press the caliper piston into the caliper bore, being careful not to cock the caliper piston.
3. Install the disc brake caliper.