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Home › Ford › 2000 › ZX2 Standard › Repair and Diagnosis › External Pages › Different car › Section 1565 (Rear Disc Brake System) › Disassembly And Assembly › Rear Brake Caliper › Disassembly and Assembly

Disassembly and Assembly

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the brake caliper. For additional information, refer to BRAKE CALIPER  or BRAKE CALIPER - HYBRID .
  2. Secure the brake caliper in a vise.
  3. Remove the brake caliper dust boot.
  4. Remove the bleeder screw cap.
  5. Remove the bleeder screw.
    • To install, tighten to 16 Nm (12 lb-ft).
    6. CAUTION: Apply moderate air pressure in short bursts to prevent an uncontrolled release of the piston.
    NOTE: Inspect the brake caliper piston and bore for excessive wear, corrosion or pitting. If any of these conditions exist, a new caliper must be installed.
  6. Remove the brake caliper piston.
    1. Place a block of wood between the brake caliper piston and the brake caliper housing.
    2. Apply compressed air through the brake caliper jounce hose port to remove the piston.
      Fig 1: Identifying Block Of Wood And Brake Caliper Jounce Hose Port
      G04617690Courtesy of FORD MOTOR CO.
  7. Remove the dust boot.
    8. CAUTION: Use a plastic or wooden pick to remove the piston seal from the caliper bore. A metal tool may scratch or nick the seal groove, which could result in a seal leak.
  8. Remove the piston seal using a plastic or wooden tool.
  9. To assemble, reverse the disassembly procedure.
    • Lubricate the piston seal with clean brake fluid.
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