Caliper

Dual Piston

Disassembly

1. Disconnect the front brake hose (2078) and plug the end to prevent brake fluid leakage. Remove the disc brake caliper as described in this section.

2. Remove the brake shoes and linings (2001) and disc brake pad anti-rattle clip.

3. Drain the fluid from the disc brake caliper.

4. Secure the disc brake caliper in a vise.

5. Place a block of wood between the caliper bridge and the caliper pistons and apply low-pressure air to the fluid port in the disc brake caliper with an air nozzle equipped with Rubber Tipped Air Gun D93L-7000-A or equivalent to remove the caliper pistons (2196). The caliper pistons will be forced out to the wood block.

   

6. Remove the wood block and remove the caliper pistons.

7. Remove and discard the piston seals and boots.

8. NOTE: Do not hone the cylinder bores. Piston assemblies are not available for honed cylinder bores.

   If the disc brake caliper is leaking, replace the piston assemblies. If the cylinder bores are excessively scored or corroded, replace the disc brake caliper.

   

   Item	Part Number	Description
   1	—	Piston Boot (Part of 2B120)
   2	—	Piston Seal (Part of 2B120)
   3	2B120	Disc Brake Caliper
   4	2B164	Disc Brake Pad Anti-Rattle Clip
   5	2001	Brake Shoe and Lining
   6	—	Bleeder Screw (Part of 2B120)
   7	2196	Caliper Piston

Assembly

1.  CAUTION: Never reuse piston seals and dust boots. Install a new set each time the disc brake caliper is assembled.

   Lubricate new piston seals with Ford High Performance Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A and install into cylinder bore seal grooves.

2. Apply a film of clean brake fluid to the cylinder bores.

3. Lubricate the retaining lips of the dust boots with clean brake fluid and install into the boot retaining grooves in the cylinder bores.

4. Apply a film of clean brake fluid to the caliper pistons.

5. Insert the caliper pistons into the dust boots and start them into the cylinders by hand until they are beyond the piston seals. Be careful not to damage or dislodge the piston seal.

6. Place a wood block over one caliper piston and press the caliper piston into the cylinder being careful not to cock the caliper piston in the cylinder. Install the second caliper piston in the same manner. Seat boots correctly.

7. Install the brake shoe and lining and disc brake pad anti-rattle clip in the disc brake caliper. Place the disc brake caliper on the front wheel spindle and install the caliper pins.

8. Install the front brake hose with new copper washers and tighten to specification listed at the end of this section.

9. Bleed the brake system. Refer to Section 06-06.Do not move the vehicle until a firm brake pedal (2455) is obtained.

Single Piston

NOTE: Do not use a screwdriver or any similar tool to pry caliper piston into or out of the bore. This will prevent chipping or scuffing damage to the phenolic piston.

Disassembly

1. Remove the disc brake caliper from the vehicle. Refer to Caliper Removal in this section.

2. Place a cloth over the caliper piston before applying air pressure to prevent damage to the caliper piston.

3. Apply air pressure to the fluid port in the disc brake caliper with an air nozzle equipped with Rubber Tipped Air Gun D93L-7000-A or equivalent to remove the caliper piston.

4. NOTE: Use care because the caliper piston can develop considerable force from pressure buildup.

   If the caliper piston is seized and cannot be forced from the disc brake caliper, tap lightly around the caliper piston while applying air pressure.

5. NOTE: Do not remove the steel ring from the caliper piston.

   Remove the dust boot from the disc brake caliper.

6. Remove the rubber piston seal from the cylinder, and discard it.

   Disc Brake Caliper, Disassembled, LD Sliding Caliper

   

   Item	Part Number	Description
   1	2207	Dust Boot (Part of 2B120)
   2	2196	Caliper Piston
   3	2B120	Disc Brake Caliper
   4	2B115	Seal (Part of 2B120)

Assembly

1. NOTE: Use Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.

   Apply a film of clean brake fluid to the new caliper piston seal, and install it in the cylinder bore. Be sure the seal does not become twisted but is firmly seated in the groove.

2. Install a new dust boot by setting the flange squarely in the outer groove of the caliper bore.

3. NOTE: Use Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.

   Coat the caliper piston with brake fluid, and install the caliper piston in the cylinder bore. Spread the dust boot over the caliper piston as it is installed. Seat the dust boot in the piston groove, behind the pressed on steel ring.

4. Install the front brake hose with new copper washers and tighten to specification listed at the end of this section.

5. Bleed the brake system. Refer to Section 06-06. Do not move the vehicle until a firm brake pedal is obtained.