AutoZone 1990 Honda Accord 2.2L FI 4cyl | Repair Guides | Brakes | Disc Brakes | Brake Caliper | AutoZone.com

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    Ford Escort/Tracer 1991-1999 Repair Guide

    Brake Caliper

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    REMOVAL & INSTALLATION



    Front Brakes

    See Figures 1 through 6

    A scan tool is absolutely necessary to bleed the brake hydraulic system on 1997-99 models equipped with an Anti-lock Brake System (ABS). If your vehicle is equipped with ABS, be sure to refer to the ABS bleeding procedures in this section before performing any work on your vehicle's brake hydraulic system.

    1. Raise and safely support the vehicle.
    2.  
    3. Remove the wheel and tire assembly.
    4.  
    5. Remove the disc brake pads.
    6.  
    7. Unfasten the two brake caliper retaining bolts and remove the brake caliper.
    8.  
    9. Either support the caliper with a piece of mechanic's wire, or unfasten the banjo bolt securing the brake hose to the brake caliper and remove the caliper from the vehicle. Discard the two copper sealing washers.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 1: If necessary, remove the clip that attaches the hose to the front strut



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    Fig. Fig. 2: Unfasten the disc brake caliper retaining bolts (arrows)



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    Fig. Fig. 3: Remove the caliper assembly from its mounting ...



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    Fig. Fig. 4: ... and support the caliper with a piece of mechanic's wire



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    Fig. Fig. 5: Unfasten the banjo bolt securing the brake hose to the brake caliper ...



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    Fig. Fig. 6: ... then detach the brake hose and discard the copper washers

    To install:
    1. Place the brake caliper in position and install the two brake caliper retaining bolts. Tighten the bolts to 29-36 ft. lbs. (39-49 Nm) on 1991-96 models and 36-43 ft. lbs. (49-59 Nm) on 1997-99 models.
    2.  
    3. If removed, attach the brake hose to the brake caliper and install the banjo bolt with two new copper sealing washers. Tighten the banjo bolt to 16-20 ft. lbs. (22-29 Nm).
    4.  
    5. Install the disc brake pads.
    6.  
    7. Bleed the brake system.
    8.  
    9. Install the wheel and tire assembly.
    10.  
    11. Lower the vehicle.
    12.  
    13. Pump the brake pedal several times to position the brake pads to the brake rotor.
    14.  
    15. Road test the vehicle and check the brake system for proper operation.
    16.  

    Rear Brakes

    A scan tool is absolutely necessary to bleed the brake hydraulic system on 1997-99 models equipped with an Anti-lock Brake System (ABS). If your vehicle is equipped with ABS, be sure to refer to the ABS bleeding procedures in this section before performing any work on your vehicle's brake hydraulic system.

    1. Raise and safely support the vehicle.
    2.  
    3. Remove the wheel and tire assembly.
    4.  
    5. Remove the disc brake pads.
    6.  
    7. Remove the parking brake cable bracket bolt and position the bracket aside.
    8.  
    9. Remove the parking brake cable from the operating lever.
    10.  
    11. Unfasten the banjo bolt securing the brake hose to the brake caliper. Discard the two copper sealing washers.
    12.  
    13. Remove the upper brake caliper retaining bolt.
    14.  
    15. Slide the brake caliper off the mounting bracket and remove from the vehicle.
    16.  

    To install:
    1. Place the brake caliper on the mounting bracket and slide into position.
    2.  
    3. Install the upper brake caliper retaining bolt. Tighten the bolt to 33-43 ft. lbs. (45-59 Nm).
    4.  
    5. Install the brake hose to the brake caliper and secure with the banjo bolt using two new copper sealing washers. Tighten the banjo bolt to 16-22 ft. lbs. (22-29 Nm).
    6.  
    7. Connect the parking brake cable to the operating lever. Position the bracket and install the bracket bolt.
    8.  
    9. Install the disc brake pads.
    10.  
    11. Bleed the brake system.
    12.  
    13. Install the wheel and tire assembly.
    14.  
    15. Adjust the parking brake.
    16.  
    17. Lower the vehicle.
    18.  
    19. Pump the brake pedal several times to position the brake pads to the brake rotor.
    20.  
    21. Road test the vehicle and check the brake system for proper operation.
    22.  

    OVERHAUL



    See Figures 7 through 14

    A scan tool is absolutely necessary to bleed the brake hydraulic system on 1997-99 models equipped with an Anti-lock Brake System (ABS). If your vehicle is equipped with ABS, be sure to refer to the ABS bleeding procedures in this section before performing any work on your vehicle's brake hydraulic system.

    Some vehicles may be equipped with 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.  



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    Fig. Fig. 7: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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    Fig. Fig. 8: 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.  



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    Fig. Fig. 9: 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.  



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    Fig. Fig. 10: Use a prytool to carefully pry around the edge of the boot ...



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    Fig. Fig. 11: ... 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.  



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    Fig. Fig. 12: 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. 13: 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. 14: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

     
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