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Front Brake Caliper: Disassembly

WARNING: This page is about a different car, the 2005 Lincoln Navigator and 2005 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the disc brake caliper. For additional information, refer to BRAKE CALIPER .
  2. Drain the remaining brake fluid from the disc brake caliper.
  3. Secure the disc brake caliper in a vise.
  4. Remove the caliper pistons (2196).
    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 pistons to the block of wood.
    4. Remove the block of wood and the caliper pistons.
  5. Remove and discard the piston seals and boots.
    Fig 1: Removing Piston Seals And Boots
    G03928708Courtesy of FORD MOTOR CO.
    6. NOTE: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores.
    Fig 2: Replacing Disc Brake Caliper
    G03928709Courtesy of FORD MOTOR CO.
  6. If the cylinder bores are excessively scored or corroded, replace the disc brake caliper.
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