AutoZone 2000 Honda Accord DX 2.3L MFI 4cyl | Repair Guides | Brakes | Front Disc Brakes | Calipers | AutoZone.com

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    Ford Ranger/Explorer/Mountaineer 1991-1999

    Calipers

    Print

    See Figures 1 and 2



    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of the single piston caliper



    Click image to see an enlarged view

    Fig. Fig. 2: Cross-sectional view of the dual piston caliper

    REMOVAL & INSTALLATION



    See Figures 3, 4 and 5

    1. Follow the procedures for pad removal earlier in this section.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 3: Loosen the brake hose-to-caliper retaining bolt ...

    1. Remove the brake hose-to-caliper attaching bolt.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 4: ... then remove it, along with the hose fitting and the sealing washers



    Click image to see an enlarged view

    Fig. Fig. 5: Always discard the old sealing washers and use new ones when installing the caliper

    1. Discard the brass washers and plug the brake hose and caliper bolt hole.
    2.  
    3. On dual piston caliper models, and if necessary, remove the brake pad anchor plate by removing the two attaching screws from the back of the steering knuckle.
    4.  
    5. Inspect the caliper, piston and rubber seals/boots for damage and replace as necessary.
    6.  

    To install:
    1. On dual piston calipers, and if removed, position the anchor plat to the steering knuckle and install the two retaining bolts. Use a threadlocking compound on the old bolts or install new bolts and tighten them to 73-97 ft. lbs. (98-132 Nm).
    2.  
    3. If it was necessary to remove the brake pads, install them to the anchor plate (dual piston) or caliper (single piston).
    4.  
    5. Install the caliper as instructed in the brake pad installation procedures.
    6.  

    Always use new sealing washers when assembling the hose to the brake caliper.

    1. Place a new sealing washer on the brake hose bolt, slide the bolt through the hose fitting and install a second sealing washer to the bolt.
    2.  
    3. Position the hose/bolt to the caliper then tighten the bolt to 1-29 ft. lbs. (30-40 Nm).
    4.  
    5. Bleed the brake system. Check for leaks and proper operation before placing the vehicle into service.
    6.  

    OVERHAUL



    See Figures 6 through 11

    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.

        Click image to see an enlarged view

        Fig. Fig. 6: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



        Click image to see an enlarged view

        Fig. Fig. 7: Withdraw the piston from the caliper bore

      4.  

    2.  
    3. For the second method, you must rotate the piston to retract it from the caliper.
    4.  
    5. If equipped, remove the anti-rattle clip.
    6.  
    7. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
    8.  



    Click image to see an enlarged view

    Fig. Fig. 8: Use a prytool to carefully pry around the edge of the boot ...



    Click image to see an enlarged view

    Fig. Fig. 9: ... 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. 10: 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. 11: 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.  

     
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