Ford Freestar, Monterey 2004-2006

Brake Caliper

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Removal & Installation



  1. Remove and discard 1 / 2 of the brake fluid from the brake master cylinder reservoir.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. Disconnect the brake hose from the disc brake caliper by loosening and removing the hollow retaining bolt. Discard 2 copper sealing washers and plug the brake hose.
  8.  
  9. Using a C-clamp or equivalent, position the clamp frame on the inboard side of the disc brake caliper housing. Place the clamp screw on the outboard disc brake pad and tighten the clamp enough to press the caliper piston into the caliper housing releasing pressure on the disc brake pads.
  10.  
  11. Disconnect the parking brake cable from the caliper.
  12.  
  13. Remove 2 disc brake caliper retaining bolts.
  14.  
  15. Remove the caliper by swinging out the bottom of the caliper first.
  16.  
  17. Remove the disc brake pads, if necessary.
  18.  
  19. Remove the caliper anchor bracket, if necessary.
  20.  

To install:

  1. If removed, install the caliper anchor bracket. Tighten the bolts to 75 ft. lbs. (102 Nm).
  2.  
  3. Retract the disc brake caliper piston fully into the caliper bore using a C-clamp and block of wood or equivalent.
  4.  
  5. Ensure that the disc brake pads are properly positioned and that the lining material is facing the rotor.
  6.  
  7. Install the caliper over the disc brake rotor and position on the brake adapter. Install 2 disc brake caliper retaining bolts and starting with the bottom bolt first, tighten to 24 ft. lbs. (33 Nm).
  8.  
  9. Install the parking brake cable to the caliper.

    Click image to see an enlarged view

    Fig. Exploded view of the rear disc brake caliper assembly-Freestar and Monterey

  10.  
  11. Unplug and install the brake hose and hollow retaining bolt to the disc brake caliper using a new copper sealing washer on each side of the hose fitting. Tighten the retaining bolt to 41 ft. lbs. (55 Nm).
  12.  
  13. Bleed the brake system and install the rubber bleeder screw caps when complete.
  14.  
  15. Install the wheel and tire assembly. Torque the lug nuts to 100 ft. lbs. (136 Nm).
  16.  
  17. Lower the vehicle.
  18.  
  19. Pump the brake pedal several times to position the brake pads before attempting to move the vehicle.
  20.  
  21. Check and fill the brake master cylinder as required.
  22.  
  23. Road-test the vehicle and check for proper brake operation.
  24.  

 
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