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    Ford Crown Victoria, Mercury Grand Marquis, Marauder, Lincoln Town Car 1999-2005

    Brake Caliper

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    Overhaul




    NOTE
    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!


    NOTE
    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. 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. 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. 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. Use a prytool to carefully pry around the edge of the boot . . .



    Click image to see an enlarged view

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

     
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