- Raise the vehicle until the wheel and tire clear the floor. Place safety stands under the vehicle.
- Remove the wheel cover.
- Remove the wheel and tire from the hub and disc.
- Visually check the caliper for signs of leakage. If leakage is evident, the caliper should be overhauled or replaced.
- Install the wheel and tire assembly and tighten the wheel lug nuts. Install the wheel cover.
- Remove the safety stands and lower the vehicle.
REMOVAL & INSTALLATION
- Raise and safely support the vehicle. Remove the wheel cover.
- Remove the wheel and tire assembly from the hub. Be careful to avoid damage to or interference with the caliper splash shield or bleeder screw fitting.
Disconnect the flexible brake hose from the caliper as follows:
- Disconnect the hose, and loosen the tube fitting that connects the hose to the brake tube at the bracket on the frame. Plug the brake tube.
- Remove the horseshoe shaped retaining clip from the hose and bracket.
- Disengage the hose from the bracket, and unscrew the entire hose assembly from the caliper.
- Remove the caliper locating pins. If they have Torx® heads, use Caliper Pin Remover/Installer D79P-2100-T45, or equivalent.
- Lift the caliper assembly from the integral spindle/anchor plate and rotor.
- Install the caliper assembly over the rotor with the outer brake shoe against the rotor's braking surface.
- Lubricate the rubber insulators with 4-8 grams of silicone dielectric compound or equivalent.
- Install new locating pins (except for Mustang SVO, whose pins can be re-used), and hand thread them into the spindle/anchor plate assembly. Be sure that the pins are free from oil, grease and dirt.
- Tighten the caliper locating pins to 30-40 ft. lbs. (40-60 ft. lbs. on Mustang SVO). If they have Torx® heads, use Caliper Pin Remover/Installer D79P-2100-T45 or equivalent.
- For all vehicles except Mustang SVO, thread the flexible brake hose into its fitting on the caliper and tighten to 20-30 ft. lbs. This is a special self-sealing fitting that does not require a gasket.
When the hose is correctly tightened, there should be one or two threads of the fitting exposed. Do not overtighten.
- On Mustang SVO, install the flexible brake hose to the caliper with a hollow bolt and two new sealing washers. Tighten the hose fitting to 17-25 ft. lbs.
- Position the upper end of the flexible brake hose in its bracket, and install the retaining clip. Do not twist the hose.
- Remove the plug from the brake tube. Connect the tube to the brake hose with the tube fitting nut, and tighten to 10-18 ft. lbs.
- Bleed the brake system and centralize the brake pressure differential valve.
- Top off the master cylinder to the specified level with new brake fluid.
- Install the wheel and tire assembly and tighten the wheel lug nuts.
- Install the wheel cover and lower the vehicle.
- Apply the brake pedal several times to position the brake linings.
- Road test the vehicle.
See Figures 1, 2, 3, 4, 5 and 6
- Remove the caliper assembly from the vehicle as outlined above.
- Place a cloth over the piston before applying air pressure to prevent damage to the piston.
Mustang SVO is equipped with a phenolic (plastic) piston. Before air pressure is applied, insert layers of shop towels to cushion the possible impact of the piston against the caliper iron. Do not use a screwdriver or similar tool to pry the piston out of its bore, since damage to the phenolic piston may result.
- Apply air pressure to the fluid port in the caliper with a rubber tipped nozzle to remove the piston. If the piston is seized and cannot be forced from the caliper, tap lightly around the piston while applying air pressure. Use care, because the piston can develop considerable force from pressure buildup.
- Remove the dust boot from the caliper assembly.
- Remove the rubber piston seal from the cylinder, and discard it.
- Clean all metal parts with isopropyl alcohol. Then, clean out and dry the grooves and passageways with compressed air. Make sure the caliper bore and component parts are thoroughly clean.
- Check the cylinder and piston for damage or excessive wear. Replace the piston if it is pitted, scored, corroded, or the plating is worn off. Do not replace a phenolic piston for cosmetic surface irregularities or small chips between the piston boot groove and shoe face.
- Apply a film of clean brake fluid to the new caliper piston seal, and install it in the cylinder. Be sure the seal does not become twisted but is firmly seated in the groove.
- Install a new dust boot by seating the flange squarely in the outer groove of the caliper bore.
- Coat the piston with brake fluid, and install the piston in the cylinder. Be sure to use a wood block or other flat stock when using a C-clamp to install the piston back into the cylinder. Never apply the C-clamp directly to a phenolic piston, and be sure the piston is not cocked. Spread the dust boot over the piston as it is installed. Seat the dust boot in the piston groove.
- Install the caliper over the rotor and reconnect the brake hose, as outlined above.
- Bleed the brake system.