AutoZone 1969 Ford GT40 4.7L 4BL 8cyl | Repair Guides | Brakes | Disc Brakes | Brake Caliper | AutoZone.com

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    Ford Windstar 1995-1998 Repair Guide

    Brake Caliper

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    CAUTION
    Older brake pads or shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

    REMOVAL & INSTALLATION



    See Figures 1 and 2



    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of a brake caliper assembly



    Click image to see an enlarged view

    Fig. Fig. 2: Exploded view of a rear disc brake assembly

    Front
    1. Remove the brake master cylinder reservoir cap. Siphon and recycle approximately half the fluid from the reservoir.
    2.  
    3. Raise and support the vehicle safely.
    4.  
    5. Remove the wheels.
    6.  
    7. Matchmark the brake caliper to ensure it is installed on the proper side of the vehicle during installation.
    8.  
    9. Place a drain pan under the caliper to catch dripping brake fluid.
    10.  
    11. Remove the hollow retaining bolt that connects the hose to the caliper. Discard the copper washers.
    12.  
    13. Remove the brake hose and cap to prevent the entry of moisture or dirt.
    14.  
    15. Remove the disc brake caliper guide pins.
    16.  
    17. Lift the disc brake caliper from the anchor plate.
    18.  

    To install:
    1. Use a C-clamp and wooden block to seat the disc brake caliper hydraulic piston in its bore, as illustrated.
    2.  
    3. Clean the brake rotor and caliper of all contaminates using commercially available brake cleaning fluid. If brake pads have become contaminated replace them with a new set.
    4.  
    5. Install the disc brake caliper onto the anchor plate.
    6.  
    7. Install the disc brake caliper guide pin and tighten to 23-38 ft. lbs. (31-38 Nm).
    8.  
    9. Connect the brake hose, using two new copper washers and tighten hollow bolt to 35-46 ft. lbs. (47-63 Nm).
    10.  
    11. Fill the master cylinder fluid reservoir with clean, fresh brake fluid meeting or exceeding DOT 3 specifications.
    12.  
    13. Bleed the brake system.
    14.  

    Failure to tighten the lug nuts to the proper torque in a star pattern may result in damage to the brake rotor.

    1. Install the wheel and tighten lug nuts to 83-112 ft. lbs. (113-153 Nm).
    2.  
    3. Lower the vehicle.
    4.  

    Rear

    1. Remove the brake master cylinder reservoir cap. Siphon and recycle approximately half the fluid from the reservoir.
    2.  
    3. Raise and support the vehicle safely.
    4.  
    5. Remove the wheels.
    6.  
    7. Matchmark the brake caliper to ensure that it will be installed on the proper side of the vehicle.
    8.  
    9. Place a drain pan under the caliper to catch dripping brake fluid.
    10.  
    11. Remove the hollow retaining bolt that connects the hose to the caliper. Discard the copper washers.
    12.  
    13. Remove the brake hose and cap to prevent the entry of moisture or dirt.
    14.  

    Do not press against the brake pad spring clip.

    1. Position the C-clamp frame on the inboard side of the rear disc brake caliper housing. Position the clamp screw on the outboard brake pad backing plate.
    2.  
    3. Tighten the C-clamp sufficiently to press the rear disc brake caliper piston to the bottom of the caliper bore.
    4.  
    5. Remove the caliper bolts.
    6.  

    Do not allow the caliper to hang by the rear brake hose.

    1. Work the caliper off the rear disc brake rotor and brake adapter.
    2.  

    To install:

    To prevent interference with rear disc brake caliper operation, verify correct caliper bolt length. The shank portion including the threads of the caliper bolt should not be more than 2.613-2.661 in. (66.4-67.6mm).

    1. Install the rear disc brake caliper on the rotor. Make sure the notches on the upper ends of the brake pad are seated over the upper ledge of the adapter and the brake pad lower tabs are positioned on the lower ledge of the adapter.
    2.  
    3. Lubricate the caliper bolts with Disc Brake Caliper Slide Grease (D7AZ-19590-A) or equivalent. Install and tighten to 11-14 ft. lbs. (15-20 Nm).
    4.  

    Failure to tighten the lug nuts to the proper torque in a star pattern may result in damage to the brake rotor.

    1. Connect the brake hose, using two new copper washers and tighten the hollow bolt to 35-46 ft. lbs. (47-63 Nm).
    2.  
    3. Fill the master cylinder fluid reservoir with clean, fresh brake fluid meeting or exceeding DOT 3 specifications.
    4.  
    5. Bleed the brake system.
    6.  
    7. Install the wheel and tighten lug nuts to 83-112 ft. lbs. (113-153 Nm).
    8.  
    9. Lower the vehicle.
    10.  

    OVERHAUL



    See Figures 3, 4, 5, 6, 7, 8, 9 and 10

    Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

    1. Remove the caliper from the vehicle and place on a clean workbench.
    2.  


    CAUTION
    NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

    Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

    1. The first method is as follows:
      1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
      2.  
      3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
      4.  

    2.  



    Click image to see an enlarged view

    Fig. Fig. 3: For some types of calipers, use compressed air to drive out the piston, but be sure to keep your fingers clear



    Click image to see an enlarged view

    Fig. Fig. 4: Withdraw the piston from the caliper bore

    1. For the second method, you must rotate the piston to retract it from the caliper.
    2.  
    3. If equipped, remove the anti-rattle clip.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 5: On some vehicles, you must remove the anti-rattle clip

    1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 6: Use a prytool to carefully pry around the edge of the boot ...



    Click image to see an enlarged view

    Fig. Fig. 7: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

    1. Remove the piston seals from the groove in the caliper bore.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 8: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

    1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
    2.  
    3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
    4.  
    5. Use crocus cloth to polish out light corrosion from the piston and bore.
    6.  
    7. Clean all parts with denatured alcohol and dry with compressed air.
    8.  

    To assemble:
    1. Lubricate and install the bleeder valve and cap.
    2.  
    3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
    4.  
    5. Lubricate the piston bore.
    6.  
    7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
    8.  
    9. Use a suitable driving tool to seat the boots in the housing.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 9: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

    1. Install the caliper in the vehicle.
    2.  
    3. Install the wheel and tire assembly, then carefully lower the vehicle.
    4.  
    5. Properly bleed the brake system.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 10: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

     
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