Brake Caliper

REMOVAL & INSTALLATION

1. Raise and safely support the front of the vehicle on jackstands. Set the parking brake and block the rear wheels.
2. Siphon a sufficient amount of brake fluid from the master cylinder reservoir to prevent the brake fluid from overflowing when removing or installing the caliper. This is necessary as the piston must be forced into the cylinder bore to provide clearance to install the caliper.
3. Remove the wheel.

   NOTE: Disassemble brakes one wheel at a time. This will prevent parts confusion and also prevent the opposite piston from popping out during installation.

4. Disconnect the brake line at the clip on the strut and disconnect the hose union at the caliper. Use a pan to catch any spilled fluid and immediately plug the hose end.
5. Remove the two caliper mounting bolts and then remove the caliper from the mounting bracket. Alternatively, remove the two bolts (screwed directly into the backing plate) which fasten the caliper support to the backing plate, and remove the entire assembly. Remove the brake pads and clips from the support as described above. Remove the lockpin (lower) and guide pin (upper) from the caliper support, and remove the caliper from the support.

   Fig. 1: To remove the piston from the caliper body, use compressed air to blow it out — 1992–95 Monteros

   Fig. 2: Use your fingers to remove the piston seal, because sharp or hard tools can scratch or gouge the piston bore

   To install:

6. Use a caliper compressor, a C-clamp or a large pair of pliers to slowly press the caliper piston back into the caliper.
7. If the mounting plate was removed from the backing plate, reinstall it and coat the bolts with an anti-seize compound. Tighten the bolts to 66 ft. lbs. (90 Nm).
8. Install the pads onto the mount and install the caliper. Make sure the slide bushings and bolts are clean and properly lubricated. Do not use regular grease or spray lubricants; they cannot withstand the extreme heat generated by the brakes. Tighten the upper and lower bolts to 23–30 ft. lbs. (32–42 Nm).
9. Connect the fluid hose to the caliper and then to the hard line at the body. Tighten each fitting to 12 ft. lbs. (17 Nm) and make sure the hose is correctly routed and not kinked. Remember to install any clips or retainers holding the line.
10. Refill the master cylinder reservoir to the MAX line. Bleed the brake system. Keep a close eye on the reservoir, maintaining its level at at least half during the bleeding. Since the caliper was emptied, a fair amount of brake fluid may need to be added.
11. Reinstall the wheel and lower the vehicle to the ground.
12. Check the level in the fluid reservoir and top it off as needed. Before driving the car, start the engine and operate the brake pedal several times to check the feel and engagement point of the brakes.